How To: Radiator Stack Removal and Install - Chevy and GMC Duramax Diesel Forum
How To's, DIY and Write ups DuramaxForum How To's, Do it Yourself Guides, and other write ups. Only How TO post belong in this forum!!! If your NOT showing/telling us HOW TO then DO NOT post it here.

 14Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 235 (permalink) Old 08-31-2013, 05:55 PM Thread Starter
Duramax Lifetime Supporter
 
nmeyer414's Avatar
 
Join Date: Aug 2011
Posts: 1,927
How To: Radiator Stack Removal and Install

ok since this has not been done before or if it has it has been hidden in the millions of threads on this forum, I went ahead and decided to take some pics of how to remove, clean and install the radiator stack. this should pertain to all OBS trucks since I have an LBZ and it is generally the same for the LLY and LB7.

Symptoms:
1. truck is running a little hot.
2. transmission is running a little hot.
3. A/C is not quite as cold as it was before. (should be done before this https://www.duramaxforum.com/forum/di...evap-coil.html )
4. truck is operated in dirty/dusty generally nasty conditions.
5. you have changed out the thermostats and have done a complete DEX-cool flush but engine is still running kind of hot.

now this is not a cure all for some of these conditions, because maybe you need to change fluids, maybe something else is going on to cause the issues, etc. this is a how to for removal and reinstall of the coolant stack whether just cleaning them like I did or having to replace them for what ever reason. it is a good service to add to your yearly maintenance routine as well.

so lets start with what you will need to accomplish this project.

before you begin:

1. you need to get you some engine cleaner/degreaser
2. get a good pressure washer. one that will easily remove the garbage that has collected on your coolant stack but not so powerful. you have to remember that you will be spraying it on the fins of the radiators and around electronic equipment.
3. make sure that you have you plenty of good hydration beverage, like me I had me some Gatorade and water because I was out in the TX. sun during the middle of the day.
4. below is a list of tools that you will need to accomplish this mission
5. if I have forgotten something them by all means make sure that you acquire it before you start this project.
6. MAKE SURE YOU HAVE AT LEAST 4 HOURS FOR THIS, 1.5 FOR REMOVAL AND 1.5 FOR REASSEMBLE, AND 1 HOUR AS A BUFFER/BOO BOO LIP COOL DOWN TIME

list of tools needed

1. body clip removal tool
2. long needle nose pliars and a magnetic retrieving tool (to retrieve something if you drop it)
3. socket wrench with a couple extensions and a swivel joint. (I used 1/4" drive because none of the bolts were that big or tight that constituted anything above 3/8" drive.)
4. sockets in these sizes 10mm, 7/16", 1/2"
5. a T25 TORX head (bit/screw driver/wrench whatever you choose) there are only 4 bolts/screws that you will have to remove with this.
6. you can add a good flat tip screw driver and channel locks to the list.
Attached Images
File Type: jpg engine cleaner.jpg (63.4 KB, 3408 views)
File Type: jpg 2.jpg (38.0 KB, 3402 views)
File Type: jpg 1.jpg (53.8 KB, 3370 views)
File Type: jpg water.jpg (6.2 KB, 3273 views)
File Type: jpg gatorade.jpg (111.8 KB, 3268 views)

NATE

2018 GMC SIERRA 2500HD DENALI
2006 LBZ (Regency Edition) sold

http://real-man-truckworks-and-survi...p?action=forum


Last edited by nmeyer414; 09-01-2013 at 06:58 AM.
nmeyer414 is offline  
Sponsored Links
Advertisement
 
post #2 of 235 (permalink) Old 08-31-2013, 06:06 PM Thread Starter
Duramax Lifetime Supporter
 
nmeyer414's Avatar
 
Join Date: Aug 2011
Posts: 1,927
ok, now that we have all of the gathering, acquiring, preparing issues covered lets start.

1. ensure that your vehicle has been sitting over night so that you will not burn yourself with hot fluids and metals.
2. open the hood and remove the plastic covering the hood release
3. remove the air cleaner, air cleaner box and the intake tubing
4. remove the grill guard by lightly pulling or pushing the clips free.
5. remove the pins that hold the head light assemblies in place
6. while leaving the light bulbs in the assemblies, remove the plugs from the bulbs.
7. for the lower day time running and clearance lights, there is a small plastic catch on the back of the assemblies towards the outside of each one. push that together and the assemblies will come out.
8. gently push in the catch on the back of the bulb and give it a 1/4 turn.
9. the light should pop out of the socket.

this is the same for both sides.

NATE

2018 GMC SIERRA 2500HD DENALI
2006 LBZ (Regency Edition) sold

http://real-man-truckworks-and-survi...p?action=forum

nmeyer414 is offline  
post #3 of 235 (permalink) Old 08-31-2013, 06:10 PM Thread Starter
Duramax Lifetime Supporter
 
nmeyer414's Avatar
 
Join Date: Aug 2011
Posts: 1,927
once you have both light assemblies removed from both sides, the grill, and the plastic piece covering the hood release, your vehicle should look like this.
Attached Images
File Type: jpg P1010015.jpg (68.1 KB, 3447 views)
File Type: jpg P1010016.jpg (63.3 KB, 3431 views)

NATE

2018 GMC SIERRA 2500HD DENALI
2006 LBZ (Regency Edition) sold

http://real-man-truckworks-and-survi...p?action=forum

nmeyer414 is offline  
Sponsored Links
Advertisement
 
post #4 of 235 (permalink) Old 08-31-2013, 06:23 PM Thread Starter
Duramax Lifetime Supporter
 
nmeyer414's Avatar
 
Join Date: Aug 2011
Posts: 1,927
in these next 2 pictures you will notice all of the arrows. the yellow arrows are the 4 bolts that you need to use the T25 TORX to remove them. all 6 or 12 of the blue arrows you need the 10mm along with the swivel adapter to remove them.

make sure that you pay close attention to the BIG RED arrow. that is an impact sensor and it is part of your airbag system, make sure you pay attention when you disconnect it so as not to destroy it.
Attached Images
File Type: jpg bolt removal pass side.jpg (69.3 KB, 3464 views)
File Type: jpg drivers side bolt removal.jpg (64.4 KB, 3432 views)

NATE

2018 GMC SIERRA 2500HD DENALI
2006 LBZ (Regency Edition) sold

http://real-man-truckworks-and-survi...p?action=forum

nmeyer414 is offline  
post #5 of 235 (permalink) Old 08-31-2013, 06:55 PM Thread Starter
Duramax Lifetime Supporter
 
nmeyer414's Avatar
 
Join Date: Aug 2011
Posts: 1,927
once you have all of those 16 of those bolts and the 1 sensor removed, gently pull those mounts out and lay them aside.

1. behind those mounts that you just removed there are 3 bolts per side that are (hidden) assist in holding the top cross member in place,

2. there are 2 bolts that are on the back side of the top cross member,

3. 2 bolts on the bottom of the hood catch/release support (per side),

4. 2 blots the hold the trans cooler in place to the catch/ release support, and the 2 bolts that hold the A/C cooler to the top cross member.

5. the last bolt is just above the battery on the drivers side holding the little bar to the cross member.

here are 5 pics showing all of the bolt locations.
Attached Images
File Type: jpg cross member removal locations pass side.jpg (68.8 KB, 3405 views)
File Type: jpg cross member removal locations driver side.jpg (63.8 KB, 3339 views)
File Type: jpg P1010017.jpg (52.9 KB, 3367 views)
File Type: jpg P1010030.jpg (43.0 KB, 3341 views)
File Type: jpg P1010028.jpg (60.2 KB, 3337 views)

NATE

2018 GMC SIERRA 2500HD DENALI
2006 LBZ (Regency Edition) sold

http://real-man-truckworks-and-survi...p?action=forum


Last edited by nmeyer414; 08-31-2013 at 06:58 PM.
nmeyer414 is offline  
post #6 of 235 (permalink) Old 08-31-2013, 07:03 PM Thread Starter
Duramax Lifetime Supporter
 
nmeyer414's Avatar
 
Join Date: Aug 2011
Posts: 1,927
in this next picture you will see several things.

1. the top cross member will be removed
2. the hood catch/release will be removed
3. there will be 4 arrows showing the locations of the 4 bolts that hold the intercooler and the radiator together. once you remove those 4 bolts you will have 2 more things to remove and you will be ready to separate the stack.
Attached Images
File Type: jpg P1010031.jpg (84.7 KB, 3334 views)

NATE

2018 GMC SIERRA 2500HD DENALI
2006 LBZ (Regency Edition) sold

http://real-man-truckworks-and-survi...p?action=forum

nmeyer414 is offline  
post #7 of 235 (permalink) Old 08-31-2013, 07:06 PM Thread Starter
Duramax Lifetime Supporter
 
nmeyer414's Avatar
 
Join Date: Aug 2011
Posts: 1,927
the next 2 steps involve removing the boots that hook to the intercooler on each side. once those are removed you can then separate the stack. I apologize for the lack of pictures here, I was having a boo boo lip moment and had to take a beverage break and a breather. if I have to do this again for some reason I will get some pics and edit this.

NATE

2018 GMC SIERRA 2500HD DENALI
2006 LBZ (Regency Edition) sold

http://real-man-truckworks-and-survi...p?action=forum

nmeyer414 is offline  
post #8 of 235 (permalink) Old 08-31-2013, 07:09 PM Thread Starter
Duramax Lifetime Supporter
 
nmeyer414's Avatar
 
Join Date: Aug 2011
Posts: 1,927
in these next pics you will see the stack spread apart and just how ineffective a garden hose is at getting all of the garbage out.
Attached Images
File Type: jpg P1010033.jpg (72.3 KB, 3355 views)
File Type: jpg P1010034.jpg (42.9 KB, 3340 views)
File Type: jpg P1010040.jpg (73.7 KB, 3352 views)

NATE

2018 GMC SIERRA 2500HD DENALI
2006 LBZ (Regency Edition) sold

http://real-man-truckworks-and-survi...p?action=forum

nmeyer414 is offline  
post #9 of 235 (permalink) Old 08-31-2013, 07:10 PM Thread Starter
Duramax Lifetime Supporter
 
nmeyer414's Avatar
 
Join Date: Aug 2011
Posts: 1,927
from here, your pile of parts should look something like this
Attached Images
File Type: jpg P1010041.jpg (76.6 KB, 3322 views)

NATE

2018 GMC SIERRA 2500HD DENALI
2006 LBZ (Regency Edition) sold

http://real-man-truckworks-and-survi...p?action=forum

nmeyer414 is offline  
post #10 of 235 (permalink) Old 08-31-2013, 07:16 PM Thread Starter
Duramax Lifetime Supporter
 
nmeyer414's Avatar
 
Join Date: Aug 2011
Posts: 1,927
at this point, you are ready to start with the cleaning of the coolers. spray liberal amounts of the cleaner/degreaser and let sit for 10-15 minutes.

while you are waiting the 10-15 min you should be getting your pressure washer ready as well as covering your electronics or at least identifying them so that they don't get sprayed.

once your pressure washer is ready and you have identified your important electronics, you are cleared for pressure cleaning of the coolers.

BE CAREFUL NOT TO DAMAGE THE FINS ON THE COOLERS

once all parts have been washed, let sit for 10-15 minutes to reduce the water you will be working in.

NATE

2018 GMC SIERRA 2500HD DENALI
2006 LBZ (Regency Edition) sold

http://real-man-truckworks-and-survi...p?action=forum

nmeyer414 is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Chevy and GMC Duramax Diesel Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome