Flex-a-Lite 262 User Manual

Dual Electric Fan #262

Fits 1994-2002 Dodge 2500/3500 w/ 5.9L Cummins Diesel

INSTALLATION INSTRUCTIONS

REMOVE EXISTING FAN & SHROUD:

1. Disconnect battery negative (-) cable from both batteries.

2. Make sure the engine is cool! Open the radiator cap slightly to release the

vacuum. Using the radiator valve drain located on the driver’s side, drain
enough coolant to clear the upper inlet hose of coolant. A hose or funnel will
help reduce spillage.

3. Using a 10mm socket or wrench, remove secondary battery positive (+)

cable that runs along the top of the radiator. FOR YOUR SAFETY, discon-
nect cable completely from both batteries!! see detail 1.

4. Disconnect coolant overflow bottle tube from radiator next to radiator cap.

5. Remove coolant overflow bottle from shroud by pressing on the round

“button” located at the backside of the bottle towards the shroud while lifting
up on the bottle at the same time.

6. Remove upper hose from radiator and hold off to the side for clearance.

7. Disconnect the windshield wash reservoir from the shroud by pressing the 2

locking “buttons” on the backside of the the tank towards the shroud and
lifting up at the same time. It is not required to remove the tank entirely, just

hold tank off to the side. see detail 2.

8. Using 10mm socket, remove the 4 bolts (2 left side and 2 right side) that
hold the shroud in place. KEEP these bolts for installation of new fan.

9. Remove 2 small clips that hold the top of the factory shroud to the top of
the radiator.

10. Locate lower wire harness fastened to the lower part of the factory

shroud. Unfasten harness from the factory shroud. NOTE: Do not disconnect

harness from electrical system

11. Remove OEM clutch fan. This can be accomplished by turning the large

nut on the engine side of the fan clockwise. NOTE: Careful not to let the fan

hit the radiator core when it is spun loose from the engine.

12. Lift out the fan and shroud together to avoid any damage to the radiator
core.

INST ALLATION:

1. Start by attaching the side brackets to the shrouds with hex bolts and lock

nuts provided. see detail 3.

2. Place the coolant overflow bottle on the new shroud by aligning the tab on
the bottom of the bottle with the support tab on the bottom of the shroud. Push
bottle into shroud and slide down to lock in place.

3. Locate the temperature sensor in the kit bag. Insert the temperature sensor
into the radiator fins near the radiator inlet. Leave 1/4” or less protruding
from the surface of the radiator for optimum performance. The wires will
run out through the top corner of the fan shroud. These will be used later

while wiring the VSC. see detail 4.

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DETAIL #1

DETAIL #2

INSTALLATION (CONTINUED FROM PAGE 1)

4. Place the fan into the vehicle by placing the tabs on the bottom of the shroud into the

factory slots at the bottom of the radiator. NOTE: View old shroud t abs for reference .

5. Pull the new shroud to the radiator and place the 2 small clips from the factory

shroud to the top edge of the new shroud to hold in place. see detail 5.

6. Utilizing the 4 bolts from the factory shroud and the factory mounting holes, bolt the
new fan assembly in place.

7. Secure lower electrical harness so as not to be loose

8. Install the windshield wash reservoir to the new shroud in the same way as the

coolant overflow bottle. NOTE: See step #2 of this section for reference.

9. Replace coolant overflow bottle hose to radiator. see detail 6.

10. Attach the upper “inlet” hose to the radiator. Be sure the the drain plug is closed and refill the radiator with coolant.

11. Reinstall the battery cable from the primary battery to the secondary battery using a 10mm socket.

DETAIL #4

DETAIL #5 DETAIL #6

WIRING THE VARIABLE SPEED CONTROL

FOLLOW THESE INSTRUCTIONS CAREFULLY TO AVOID DAMAGING THE CONTROL

UNIT, FAN MOTORS, AND YOUR VEHICLE! WHEN CRIMPING WIRES, ALWAYS USE A

QUALITY CRIMPING TOOL (DO NOT USE PLIERS OR OTHER DEVICES).

1. Find the thick red and black wire bundles in the wiring kit. Use the yellow butt connectors to crimp the red wire to
the short red wire on the Variable Speed Control (VSC), and the black wire to the short black wire on the VSC (see
wiring diagrams below).

2. Determine the length needed to connect the red and black power leads to the battery terminals on the primary battery

on the drivers side and trim appropriately. Crimp a large yellow ring connector to the end of the black wire and connect
to the negative (-) battery terminal but DO NOT connect the red wire yet.

3. Find a convenient place to mount the circuit breaker between the VSC and the positive (+) battery terminal and use
the 2 screws provided to mount it securely. Cut the red wire at the point where you mounted the circuit breaker. Find the

red boot for the circuit breaker and lay it on the breaker as shown in detail #7. Crimp a small yellow ring connector to

the ends of the wires and connect them to the circuit breaker. NOTE: BE SURE TO CONNECT THE END COM-

ING FROM THE BATTERY POSITIVE (+) TERMINAL TO THE “BAT” TERMINAL ON THE CIRCUIT
BREAKER (COPPER COLORED). Once both positive (+) wires are connected to the circuit breaker, fold the top of

the boot over and press to fit. This will help insulate the circuit breaker from arcing. see detail #7.

4. Crimp a large ring connector to the positive (+) battery end of the power lead and connect it to the battery terminal.

5. Locate power distribution box (fuse box). Find a circuit that is “hot” when the key is in the “ON” position. NOTE:
DO NOT use the DRL or brake/ taillight fuse! Attach the included fuse tap to the fuse. Attach a pink female connec-

tor to the thin red wire included and attach to the fuse tap. Trim the wire so that it will reach the VSC. Attach pink

female connector to the other end of the wire and connect it to terminal #9 on the VSC.

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