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How To Replace AC Condenser Cooling Fan 02-08 Dodge Ram PART 1

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How To Replace AC Condenser Cooling Fan 02-08 Dodge Ram PART 1

Created on: 2021-01-16

Check out this video to learn how to replace the AC condenser cooling fan in your 02-08 Dodge Ram. 1A Auto will guide you through the process step by step.

  1. step 1 :Remove the battery
    • Disconnect the negative battery terminal
    • Carefully disconnect the positive battery terminal
    • Use a 10 mm socket and ratchet to do this.
    • Remove the battery harness, take care not to drop the harness into the engine bay!
    • Disconnect the negative battery cable clip with your 10 mm socket and ratchet.
    • Lift the battery out.
  2. step 2 :Move the fuse relay center aside
    • Unbolt the 13 mm bolt and the Phillips push clip.
    • Slide the relay center towards the engine and then pull it aside towards where the battery was.
    • Use wire ties to fasten the fuse relay center out of the way.
  3. step 3 :Remove the AC Condenser fan
    • Remove the four bolts securing the radiator.
    • Remove the two push clips.
    • Unclip the AC line.
    • Unbolt the Condenser fan from the assembly with your 10 mm socket and ratchet.
    • Cut the fan shroud so you can remove the condenser out of the assembly.
    • Move the condenser assembly so you can finesse the fan out.
    • Swap the mounts from the old fan to the new one.
    • See part two for reassembly.

Tools needed for replacement

  • General Tools

    Razor Blade / Gasket Scraper

  • Ratchets & Related

    Socket Extensions

    Ratchet

  • Screwdrivers & Related

    Flat Blade Screwdriver

    Phillips Head Screwdriver

  • Sockets - Metric

    13mm Socket

    10mm Socket

Installation Video
Watch video

Brought to you by 1AAuto.com your source for quality replacement parts and the best service on the internet. Hi. I'm Mike Green. I'm one of the owners of 1A Auto. I want to help you save time and money repairing and maintaining your vehicle. I'm going to use my 20 plus years' experience restoring and repairing cars and trucks like this to show you the correct way to consult parts from 1AAuto.com. The right parts installed correctly: that's going to save you time and money. Thank you and enjoy the video.

Okay. This is part one of a two part video. This is removing the AC condenser fan in this 2004 Dodge Ram same as any '02 to '08. This is one of those jobs that is a whole lot easier once you know how to do it. Tools you'll need for this is a 10mm and a 13mm socket with a ratchet and extension. A tool able to cut plastic because as you can see Chrysler didn't exactly design this to be replaced easily. A flat-blade screwdriver and a Phillips screwdriver.

You want to start by removing your battery actually you can see we've already disconnected the negative cable and now we're using our 10mm wrench and we do that we a 10mm socket ratchet as well. Loosening up the positive cable with our 10mm socket ratchet and then carefully because you don't want to touch that screwdriver to anything else. You want to carefully pry off the positive battery cable. Now I'm going to fast forward a little bit but there's a 10mm bolt. Basically the middle bottom of the battery that holds the battery clamp down and you want to remove that. As you remove it the bolt that's at the bottom can slip and if you have to you can grab that with a wrench in the bottom as well.

Now you're going to use your 10mm socket with the negative ground cable from your fender and I just put that bolt back in the fender for safekeeping. You want to pull the battery towards the fender a little bit then there's basically a block, it's the bracket that holds the battery in and then you can lift the battery out and store it on a piece of wood and you don't want to store that on the concrete floor. Next you're going to want to remove your ... not remove but your fuse relay center out of the way. The 13mm bolt there and then there's a little clip that has a Phillips head pin in it that you just undo the pin and pull the pin head up out.

Then this was up and the clip comes up. Fast forward through removing that 13mm bolt. Then this really center slides towards the engine and then it pops out and then you kind of take it, move it over to where the battery was. You can see I've used some plastic wire ties and just kind of tied this up and out of the way, not too tight because I want to able to flex these wires around a little bit. Now I'm going to remove four 10mm bolts, two that hold the AC fan here and then this one here that holds the radiator shroud and all the way on the other side. There's another one here that holds the radiator shroud as well. You want to release ... there's two pins, one here and one way down here. Just use a regular screwdriver and pry those out.

Then I have to prime some, usually just grab on to them, work them back and forth and out. 10mm socket with a small extension and you can use a ratchet, obviously I'm using an air ratchet just for a little bit of quickness. I'll do a fast forward again too as I remove those four bolts and as you ... as I remove the last one the radiator... you can see the radiator kind of flex down. I just going to want that with the radiator, push back a little bit, give a little room to move around the AC condenser fan. What you want to do is remove your AC line from the clips here and then also from one way over here on the passenger side. That allows your line to go up. Now we can kind of lift up and move around your condenser and fan summary. There are four bolts that hold the condenser into the fan and assembly that are 10mm.

One's there ... one is further down there you can just kind of lift the ... there you go. Lift it up and get a better view and there's also two on this side, one there and one way further down right there. You can either reach that by reaching down there or actually from the bottom as well. My 10mm socket with the ratchet, no extension this time. A little fast forward again. As I take these bolts out you can see I just lift up the condenser and fan assembly just so I can get at the bolts and get everything out and everything. As you can see as the shroud pulled up, our condenser now is loose but Chrysler for some reason designed this so that you ... that right way to do it, I guess is to disconnect this line but you can't do that because that depressurizes your AC. It's illegal because you can't let the gases go in the air and you have to get your AC system recharged.

What you want to do is to break or cut this ... basically this piece right here so then you can get the condenser out. How you do this depends on the tools you have. I've got the snips. It goes right through the plastic pretty easy. Be careful not to damage your condenser at all. Now we're basically ready to pull it out. I've got a few things here. We got this arm that comes off the battery and make sure that we get the fan up and over it first. Then this comes apart, you have to slide the condenser over and pull the fan out. Try and show you that as best I can here. You want to bring our condenser and fan assembly up basically on top of that arm. Now pull the condenser gently out of the fan assembly here. Slip down some. I try to practice this like three times but it seems like every time it comes up a little different. Condenser moves forward here.

Try not to let the fan and the condenser hit too much, you don't want to ruin the fins. Slip the wire and stuff. The fan comes up. Here's the connector right here. Screwdriver. I knew it. Fan comes out. Here's my original fan, a new fan from 1A Auto. You're going to want to swap all your ... on the tool bar. Just pull out and push in. Mostly it is the same. I think maybe this is a different design, maybe a later or earlier design. I'll see how that installs but I am going to cut this of right here so I can get it around that hose. We're going to end this one here for now. Just checkout the part two to the same video to see the reinstallation of the fan. We hope this helps you out. Brought to you by www.1AAuto.com your source for quality replacements parts and the best service on the internet. Please feel free to call us toll free 888-844-3393. We're the company that's here for you on the internet and in person.

Brought to you by 1AAuto.com your source for quality replacement parts and the best service on the internet. Hi. I'm Mike Green. I'm one of the owners of 1A Auto. I want to help you save time and money repairing and maintaining your vehicle. I'm going to use my 20 plus years' experience restoring and repairing cars and trucks like this to show you the correct way to consult parts from 1AAuto.com. The right parts installed correctly: that's going to save you time and money. Thank you and enjoy the video.

Okay. This is part one of a two part video. This is removing the AC condenser fan in this 2004 Dodge Ram same as any '02 to '08. This is one of those jobs that is a whole lot easier once you know how to do it. Tools you'll need for this is a 10mm and a 13mm socket with a ratchet and extension. A tool able to cut plastic because as you can see Chrysler didn't exactly design this to be replaced easily. A flat-blade screwdriver and a Phillips screwdriver.

You want to start by removing your battery actually you can see we've already disconnected the negative cable and now we're using our 10mm wrench and we do that we a 10mm socket ratchet as well. Loosening up the positive cable with our 10mm socket ratchet and then carefully because you don't want to touch that screwdriver to anything else. You want to carefully pry off the positive battery cable. Now I'm going to fast forward a little bit but there's a 10mm bolt. Basically the middle bottom of the battery that holds the battery clamp down and you want to remove that. As you remove it the bolt that's at the bottom can slip and if you have to you can grab that with a wrench in the bottom as well.

Now you're going to use your 10mm socket with the negative ground cable from your fender and I just put that bolt back in the fender for safekeeping. You want to pull the battery towards the fender a little bit then there's basically a block, it's the bracket that holds the battery in and then you can lift the battery out and store it on a piece of wood and you don't want to store that on the concrete floor. Next you're going to want to remove your ... not remove but your fuse relay center out of the way. The 13mm bolt there and then there's a little clip that has a Phillips head pin in it that you just undo the pin and pull the pin head up out.

Then this was up and the clip comes up. Fast forward through removing that 13mm bolt. Then this really center slides towards the engine and then it pops out and then you kind of take it, move it over to where the battery was. You can see I've used some plastic wire ties and just kind of tied this up and out of the way, not too tight because I want to able to flex these wires around a little bit. Now I'm going to remove four 10mm bolts, two that hold the AC fan here and then this one here that holds the radiator shroud and all the way on the other side. There's another one here that holds the radiator shroud as well. You want to release ... there's two pins, one here and one way down here. Just use a regular screwdriver and pry those out.

Then I have to prime some, usually just grab on to them, work them back and forth and out. 10mm socket with a small extension and you can use a ratchet, obviously I'm using an air ratchet just for a little bit of quickness. I'll do a fast forward again too as I remove those four bolts and as you ... as I remove the last one the radiator... you can see the radiator kind of flex down. I just going to want that with the radiator, push back a little bit, give a little room to move around the AC condenser fan. What you want to do is remove your AC line from the clips here and then also from one way over here on the passenger side. That allows your line to go up. Now we can kind of lift up and move around your condenser and fan summary. There are four bolts that hold the condenser into the fan and assembly that are 10mm.

One's there ... one is further down there you can just kind of lift the ... there you go. Lift it up and get a better view and there's also two on this side, one there and one way further down right there. You can either reach that by reaching down there or actually from the bottom as well. My 10mm socket with the ratchet, no extension this time. A little fast forward again. As I take these bolts out you can see I just lift up the condenser and fan assembly just so I can get at the bolts and get everything out and everything. As you can see as the shroud pulled up, our condenser now is loose but Chrysler for some reason designed this so that you ... that right way to do it, I guess is to disconnect this line but you can't do that because that depressurizes your AC. It's illegal because you can't let the gases go in the air and you have to get your AC system recharged.

What you want to do is to break or cut this ... basically this piece right here so then you can get the condenser out. How you do this depends on the tools you have. I've got the snips. It goes right through the plastic pretty easy. Be careful not to damage your condenser at all. Now we're basically ready to pull it out. I've got a few things here. We got this arm that comes off the battery and make sure that we get the fan up and over it first. Then this comes apart, you have to slide the condenser over and pull the fan out. Try and show you that as best I can here. You want to bring our condenser and fan assembly up basically on top of that arm. Now pull the condenser gently out of the fan assembly here. Slip down some. I try to practice this like three times but it seems like every time it comes up a little different. Condenser moves forward here.

Try not to let the fan and the condenser hit too much, you don't want to ruin the fins. Slip the wire and stuff. The fan comes up. Here's the connector right here. Screwdriver. I knew it. Fan comes out. Here's my original fan, a new fan from 1A Auto. You're going to want to swap all your ... on the tool bar. Just pull out and push in. Mostly it is the same. I think maybe this is a different design, maybe a later or earlier design. I'll see how that installs but I am going to cut this of right here so I can get it around that hose. We're going to end this one here for now. Just checkout the part two to the same video to see the reinstallation of the fan. We hope this helps you out. Brought to you by www.1AAuto.com your source for quality replacements parts and the best service on the internet. Please feel free to call us toll free 888-844-3393. We're the company that's here for you on the internet and in person.

Tools needed for replacement:

    General Tools

  • Razor Blade / Gasket Scraper

  • Ratchets & Related

  • Socket Extensions
  • Ratchet

  • Screwdrivers & Related

  • Flat Blade Screwdriver
  • Phillips Head Screwdriver

  • Sockets - Metric

  • 13mm Socket
  • 10mm Socket

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2003 - 2007  Dodge  Ram 3500 Truck
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