Flex-a-Lite 264 User Manual

Dual Electric Fan #264
Fits 2003-2008 Dodge 2500/3500 w/ 5.9L & 6.7L Cummins Diesel
INSTALLATION INSTRUCTIONS
#98264 page 1 of 4 Rev. 11-16-11
DETAIL #1
DETAIL #2
REMOVE EXISTING FAN & SHROUD:
1. Make sure the engine is cool!
2. Disconnect battery negative (-) cable from both batteries.
3. Dismount windshield washer tube and battery cable from top of
shroud (3 plastic clips). See detail 1
4. On passenger side, use 10mm socket, loosen air box front
mounting point. See detail 2
5. Remove 2-13mm bolts (one on each side) from top of shroud
attached to radiator.
Note: To access bolt on passenger side, slide air box backwards.
You may need to disconnect overflow tube as well. See detail 3
6. Hold back rubber flap at the top of “floating/stock” shroud. Using
spring clamps can assist to keep flap from snapping back
into your way. See detail 4
7. Pull partial radiator side shroud out slowly from above.
8. From below, disconnect electric clutch from harness; use flat-head screw
driver to unlock connector. Harness can be found near mounting bracket
of “floating” shroud on driver’s side. See detail 5
Note: By disconnecting the electric clutch, this may cause your check
engine light to illuminate after start-up. See dealer to clear check
engine light.
9. Un-mount electric clutch wire mount using 10mm socket. Wire mount will
be attached to lower bracket of “floating” shroud on driver’s side.
See detail 6
Suggestion: Cut piece of cardboard (27” x 29” & tape to inside of core for
radiator protection).
10. Remove 2-13mm nuts securing top half of “floating” shroud, allowing
shroud to lean toward radiator core. This gives enough room for “fan clutch
mounting-nut” accessibility.
11. From below, remove 2-13mm nuts securing bottom of “floating”
shroud to bottom bracket.
12. While holding clutch pulley, use 36mm wrench & turn counter-clockwise
to loosen fan clutch mounting-nut. Be careful not to drop fan & clutch
assembly as it unscrews from pulley.
13. Slowly pull fan & clutch assembly up simultaneously with “floating”
shroud. Make sure electric clutch wire mount is free from snagging on
bottom “floating” shroud bracket.
Remove top & bottom “floating” shroud brackets.
Note: Top bracket on passenger’s side secures wiring loom. Find alternate mounting point near by and re-
secure. The 2 top brackets & 1 bottom bracket.
Note: Removal of “floating” shroud mounting brackets is for appearances only. There should be enough
clearance to install new shroud without removal of brackets.
DETAIL #3
DETAIL #4 DETAIL #5
DETAIL #6

Flex-a-Lite 264 Specifications

General

Diameter	16 inches
Blade Material	Plastic
Engine Cooling	Yes
Material	Plastic
Type	Electric
Mounting Type	Radiator
Mounting Style	Pull

Summary

INSTALLATION INSTRUCTIONS

REMOVE EXISTING FAN & SHROUD

Steps for safely removing the original fan and shroud assembly from the engine.

Prepare for Removal

Initial safety steps including cooling the engine and disconnecting power sources.

Disconnect Shroud and Harness

Detaching the shroud from the radiator and disconnecting electrical components.

Remove Fan Clutch and Shroud

Detaching the fan clutch and lifting out the original shroud assembly.

INSTALLATION OF ELECTRIC FAN & SHROUD

MOUNTING THE NEW FAN AND SHROUD

Attaching the new fan and shroud assembly to the radiator core.

Attach Fan/Shroud Brackets

Installing the passenger and driver side mounting brackets to the new shroud.

Model Year Specific Fittings

Specific installation steps for 2003 models, including overflow tank bracket.

Install Shroud, Sensor, and Hoses

Securing the new shroud, reattaching related components, and installing the temperature sensor.

WIRING THE FAN MOTOR CONTROL

CONNECTING POWER AND TRIGGER WIRES

Wiring the fan motor control unit to the vehicle's electrical system.

Wire Connections to Battery and Breaker

Connecting the main power wires and installing the circuit breaker.

Connect to Ignition, A/C, and Sensor

Tapping into ignition, A/C trigger, and temperature sensor wires.

Optional Manual Switch Wiring

Connecting an optional manual switch for fan control override.

INITIAL START-UP AND ADJUSTMENT PROCEDURES

SYSTEM VERIFICATION AND TESTING

Initial checks, engaging A/C, and verifying fan operation.

Initial Power-Up and LED Checks

Turning on the ignition and checking the status of indicator LEDs.

A/C Engagement and Fan Cycling

Engaging the A/C system to test fan response and indicator lights.

Temperature Adjustment Procedure

Adjusting the temperature sensor screw for desired fan cycling.