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Order of Removal

Top support and side plates either side of the rad.

Drain Radiator / expansion tank.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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Dodge50.co.uk

To remove the Top Crossmember you need to take the bonnet catch release wire off, this is situated right in the middle of the top crossmember, attached by a clip, you need to prise the clip off and remove the cable and hide the cable to one side.

The Top crossmember is attached at points 1, 2, 3 and 4 in the photo and you need to undo all the bolts holding it on, usually 13mm with incapsulated nuts, on the drivers side you will need to remove the screenwash water bottle held on by two 10mm headed bolts / crosshead screws to get to two of the bolts / nuts holding the side it on. In the picture 3 and 4 are the top mounting points for the rad and are usually 13mm bolts into encapsulated nuts but may be of a different size which come from the top crossmember down. You also need to remove the air filter housing mounting to the Top Crossmember.
You should now be able to remove the Top Crossmember.

The side plates either side of the rad are also bolted on with 13mm headed bolts (see 5 and 6) and When removing the passenger side sideplate you will need to remove the air filter trunking which attaches to the Air intake feed ("dodge50 horn" as we call it), by undoing the large jubilee clip, 7 or 8mm spanner / socket or flat or crosshead screwdriver.
Both side plates are attached with 3 bolts and encapsulated nuts (see 6) and also at the top (see 1 and 2) or attached through the top member.

1. Top Crossmember fittings and behind and down where the washer bottle is.
2. The other side where the Top crossmember is fitted.
3. Drivers side rad top mounting to Top Cross member.
4. Passengerside Top Rad mounting.
5. Passengerside Side Plate with "The dodge50 horn"
6. Where the side plate is fixed.

Now you need to drain the radiator, you need to have a large container for this, you need to place it under the lowest radiator pipe and undo said pipe, pull it off and let the water / coolant run out, you should also take the expansion tank cap off.

 




 

Recomended tools for the job.

13mm ring / open ended spanners, socket, 7 or 8mm spanner or cross / flat headed screwdrivers.

Something to catch the coolant in.