Radiator Removal and Reinstallation

This webpage includes many photos and will require longer-than-usual download time.

BACKGROUND: The leaking radiator on an M35A2 was removed, repaired and then reinstalled.

This page ONLY covers the removal and reinstallation.

INSTRUCTIONS: Instructions can be found in TM 9-2320-209-30-3-1, starting at page 361. The parts numbers in the instructions below match the numbers in the TM.

Personal comments ONLY pertain to the vehicle shown in the pictures and should not be construed as applicable to all M35A2 trucks.

Step by step instructions - REMOVAL


Open hood.

Step 2:

Secure hood.

Step 3:

Drain radiator by opening the petcock valve near the bottom of the radiator.

Step 4:

Using 3/4-inch wrenches, loosen two nuts (1) from two bolts (2) on the left and right sides of the brush guard ( 3).

If nuts have not been removed in years, it may help to clean them first and then apply some WD40, or engine oil, or whatever lubricant is available.

Wiggling the brush guard slightly may help remove the bolts.

Step 5:

Push up two braces (4) to unlatch braces from two bolts ( 2).

Step 6:

Using 3/4-inch wrenches, loosen two nuts (1) on two bolts (2) at left and right side of brush guard (3).

Step 7:

Lift brush guard (3) off frame brackets (4) and set brush guard aside.

This is best done by two people with one lifting each end.

Step 8:

Using 3/4-inch wrench, unscrew and take off two locknuts (1) from two radiator mounting studs (2).

The green stuff in the picture is antifreeze that had leaked out.

Step 9:

Take four flat washers (3) and two springs (4) off two radiator mounting studs (2).

Step 10:

Using 9/16-inch wrenches , unscrew and take off locknut (5) from bolt (6) at bottom right of radiator frame.

Step 11:

Take Iockwasher (7) off bolt (6) and pull ground strap (8) off bolt.

Step 12:

Take out bolt (6) .

Taking this step was NOT possible on my truck. The bolt had been spot welded to the frame on the radiator side of the frame (not visible in the picture).

Step 13:

Using screwdriver, loosen screw (1) on hose clamp (2) and slide hose clamp back on hose (3).

Step 14:

Loosen hose (3) from inlet fitting (4).

Step 15:

Using screwdriver, loosen screw (5) on hose clamp (6) and pull hose away from thermostat (7).

Step 16:

Using screwdriver, loosen screw (1) on hose clamp (2) and slide hose clamp back on hose (3).

Step 17:

Loosen hose (3) from outlet fitting (4).

Coolant may run out and splash into your face !!

Step 18:

Using 9/16-inch wrenches, unscrew and take off locknut (1) from bolt ( 2).

On my truck, this part was broken as shown in the photo.

Step 19:

Take out bolt and tilt radiator (3) forward.

Step 20:

Using 1/2-inch wrench, take out four bolts ( 4). Take off fan blade (5).

When removing radiator (3) , be very careful not to damage shroud (6) and core (7) on engine cooling fan.

Step 21:

Tilt radiator (3) forward as shown and lift radiator out of engine

Be sure not to get hung up with the drain cockpit.
Be sure the winch clutch safety is "up" and does not pinch the radiator.
Some coolant is likely still in the radiator and will run out.

Step 22:

Take two shims (8) off two radiator mounting studs (9) .

This concludes the radiator removal.



Follow instructions given in the manual. You pretty much follow the above instructions in reverse order.

The lowering of the radiator is best done by two people working together. I had one person stand on the bumper and slowly lower the radiator while I was under the truck and made sure the rubber disk cushions sat perfectly on the bolts before they slid into the holes.p

To minimize the risk of damaging the radiator on the winch lever safety, I had taped a bubble bag over the lever and safety.

The hoses fit very snugly. A large flat screwdriver was used to get them back over the inlet and outlet. Small screwdrivers can damage the hose to some extent. Large screwdrivers pose less of a risk.

Don't forget to reinstall the fan before you tighten hoses and bolt the radiator in place.

I sprayed all bolts and nuts with WD40 prior to reinstallation.



Once the radiator and fan have been reinstalled, check the system for any visible problems before you refill the radiator.

If all components and connections look good, refill the radiator with coolant. There have been several discussions on websites on which coolant to use in multifuel engines. It is my suggestion to play it safe and use heavy duty diesel engine coolant in the Deuce. You probably won't find that stuff at your local Pep Boys store. Visit a truck supplies store. You find them at truck stops along interstates and some major highways.



This was my first radiator removal and reinstallation. Following the manual made the job easy. The biggest problem I had was loosening some of the nuts that had been on the truck since it was built in 1970. Some of you may have trucks that are even older.

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