Flex-a-Lite 57291 User Manual

Note: always read instructions and verify kit contents prior to installation.

Radiator ............................................... 1ea. Electrical Connector Kit ........................ 1ea.

Pre-Mounted Fan ................................. 1ea. VSC Controller Kit ................................ 1ea.

Bracket, Top Rad. Mount Left Hand ...... 1ea. Wire Bundle ........................................ 1ea.

Bracket, Top Rad. Mount Right Hand .... 1ea. Instruction Sheet ................................. 1ea.

Mounting Hardware Kit ........................ 1ea. Flex-a-lite Decal ................................... 1ea.

Installation Instructions For:

#57001 Radiator GM Truck/SUV

#57291 Radiator & Fan GM Truck/SUV

Fits MOST 1999-2012 Vehicles

(Vehicles with automatic transmission will require cooler kit #4118GMT,

sold separately, prior to installation)

Rev. 04-01-13 #99291 Page #1 of 6

Note: To view these instructions or to view a video of this product installation, visit

www.flex-a-lite.com or call 1-800-851-1510 for assistance. It is HIGHLY recommended to

read and review these instructions prior to installation.

Removal of Old Radiator and Fan (if needed):

1. As a safety precaution, be sure the vehicle is COOL enough to work on; also disconnect the negative (-)

battery cable.

2. Open the radiator fill cap. Locate the radiator drain and drain the radiator fluid into a spill-resistant

container.

3. Remove the plastic cover from the top of the radiator that covers the front support. Use a flat-head

screwdriver to pop and release the push-clips.

4. For ease of removal and installation, remove the air intake box and tube. This will be re-installed after

final installation.

5. Remove the upper fan shroud: The fan shroud is made of a top half and a lower half. Remove the

upper hose from the radiator inlet. Release the plastic hose clamp securing upper hose routed along
top of upper shroud. Pop the push-clips that hold the upper half to the lower half. Remove the 2 upper
bolts that hold the upper shroud to the top cross member. At this point, this upper half should be free.
Remove this upper shroud from the vehicle, save the plastic factory hose clamp by removing it from
the shroud. This will be used later to re-secure the upper hose.

6. Remove the clutch fan: Support the clutch face and/or fan while spinning the nut of the fan counter-

clockwise with a 1-3/8” open-end wrench. Spin completely off and remove the fan from the vehicle.

7. Remove the lower shroud: Pull up on the lower shroud which sits in saddles with tabs.

8. Disconnect the rest of the radiator hoses: The overflow tank and steam hose will come off. Then

remove the transmission hoses (if applicable) by pulling the retaining ring away from the tank
connection and pulling the “C” clip off of the connection by pulling up with a scribe or small flat-end
screwdriver. Finally, disconnect the main outlet hose at the bottom of the radiator over the drain
container. Use a rag or plug for these ports as they may leak upon removal.

9. Remove the radiator: Remove the 2 bolts from the top flanges located at both sides of the radiator.

This will free the radiator. Tilt the radiator towards the engine and lift slowly as to not damage the
radiator or any other components. Note: Save the 4 rubber bushings from the factory radiator (2 at top
and 2 at bottom. These will be used later in the install of the new radiator.)

Installation of the New Radiator and Fan (if required):

1. Placing the radiator: Place the factory lower bushings in the lower radiator support on the vehicle. The

driver’s side may have 2 locations for placement. Use the nearest location to the center of the vehicle.
Once these are in place, lower the radiator into place as the guide pins of the new radiator seat into
the bushings.

2. Upper Radiator Mounts: Find the left and right upper mounting brackets and slide on the factory upper

bushings. Loosely mount the brackets to the left and right on the top/engine side of the radiator
utilizing the supplied T-bolts, washers and nylock nuts. Use the upper factory bolts to mount the
radiator to the original support locations. Tighten those first, then snug up the nuts on the T-bolts of
the radiator.

3. Connect Hoses: Place the hose nipples to the tanks if necessary for the overflow and the steam port

with thread tape. Do not over-tighten! Then, connect the overflow and steam port hoses. Bolt the
short side of the tube support bracket to the inside drivers side threaded insert in the shroud. Connect

Detail 1

Detail 2

the plastic factory hose clamp to this bracket then connect the larger upper inlet hose to the driver

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)

Rev. 04-01-13 #99291 Page #2 of 6

side.

4. Install the automatic transmission cooler (if applicable): Start by removing the factory grill to expose

the front side of the A/C condenser area. This consists of 4 twist-lock fasteners (2 top and 2 bottom)
turning about ¼ turn counter-clockwise to release. There is one bolt by the hood latch in the center.
When these are loose, the grill has some clips out by the headlamps that can be “gently” pulled out to
remove. The grill should come off in one piece. Note: This removal process works with the early
generation. You may need to consult your maintenance manual for newer vehicles.

5. Remove existing cooler (if applicable): Because the existing cooler is designed to run through the

radiator tank for additional cooling, there is no longer a place to connect these. Using Flex-a-lite cooler
kit #4118GMT, we can replace this with a higher capacity cooler for direct transmission cooling.
Disconnect the tubes by pulling the retaining “C” clips with a pick or small flat-head screwdriver and
remove the oil lines. Keep a drainage container and rags handy as the factory cooler still contains fluid.
Remove all the bolts holding the oil cooler and existing brackets. Retain the factory bolts for later
installation.

6. Temp Sensor: There is an ambient temperature sensor that “may” be located on the driver’s side of the

cooler. Unbolt but do not remove. Finish removing the cooler.

7. Mount #GMT4118 cooler into place with factory mounting locations and fasteners:

Note: To mount the upper portion, some models may require drilling a 7/32” hole into the support and
using the provided self-tapping screws to mount. Caution!! Do not go ALL the way thru the cooler
support; this could damage the A/C condenser.

8. Re-Install Temp Sensor: Use the bracket contained in the kit to sandwich between the bolt and the new

cooler bracket in the lower driver’s side. Attach the temp sensor with proper side facing the grill.

9. Connect Cooler Lines: Splice into the factory lines coming from the transmission. Use the barbed

adapters provided in the kit to connect the lines to the new cooler. Routing these lines to the
passenger side is ideal.

10. Replace the Fluids: Fill the radiator with the factory recommended coolant. Add factory recommended

transmission fluid to the appropriate level. Note: It is recommended to follow factory maintenance

procedures to re-fill the system and check after the engine has run for some time to verify proper levels
prior to operation.

Wiring Instructions Model #57291

1. Find a convenient location to mount the Variable Speed Control

(VSC). Note: If you choose to mount controller to face of shroud,
follow these mounting instructions. Attach the VSC directly to
the top or front face of the fan shroud. Using the holes in the

controller cover for a template, drill two 5/32” holes. Secure the

VSC with the 2ea. screws provided. (see Detail 1)

2. Drill two ¼” holes to the left of the VSC to pass the yellow and

purple wires through to the back side of the shroud (see Detail 1).

Drill one ¼” hole in the support rib on the back side of the shroud

to pass the motor wires through. (see Detail 1 & 2)

3. Place both red motor wires side by side and smoothly twist together. Completely insert pair of wires

into one end of yellow butt connector. Crimp connector to secure. Repeat with black motor wires to
another yellow insulated butt connector.
Red motor wire is (+) positive and black is (-) negative.

4. Feed the thick purple and yellow wires from the control unit

through the holes you drilled in step #2.

5. Insert yellow wire into the open end of butt connector

containing the two red motor wires and crimp connector
securely. Insert purple into the open end of butt connector
containing the two black motor wires and crimp connector
securely. (see Detail 3)

6. Determine the length of wire needed to connect the red and

black VSC power leads to the battery terminals 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.