Dodge Caravan/Plymouth Voyager Cooling System (radiator, fan, etc.)

Hi, folks,

I've moved the drum removal posts to our existing brakes discussion, where they'll have a better chance of being noticed and answered: 2001 - 2006 rear drum removal by bobconstance

#9 of 55 Re: Caravan 2001-6 Cooling Fan Relay Module [pmary] by pmary

Jan 18, 2007 (8:26 am)

Replying to: pmary (Jan 16, 2007 3:11 pm)

Hi,
After much searching I found the Relay resting on top of the front bumper (rail frame re-bar) in behind the grill on the driver's side.To access it you will need to remove the head lamp (3 screws) module.The Relay is attached (factory installed)by a large rivet. A large pry bar may be required to free the faulty relay. Remove the wiring harness with a small hooked flat screwdriver under the (hidden) inside area of the locking tab. Before re-connecting put a spot of vaseline on each tab of the new module to reduce moisture corrosion.The Relay has to be firmly re-attached to the bumper to create a heat sink.You will need to remove the rivet from the bumber with a long cold chisel and re-attach the new module with a 9/32" self tapping large screw (or see dealer's replacement part). Re-attach the wiring harness before re-attaching the module to the bumber.Make sure it is well secured- the radiator is right behind it!

Replies to this message:

pmary (Jan 21, 2007 2:17 pm)
- amduncan (Mar 09, 2007 9:20 pm)

#10 of 55 Re: Caravan 2001-6 Cooling Fan Relay Module [pmary] by pmary

Jan 21, 2007 (2:17 pm)

Replying to: pmary (Jan 18, 2007 8:26 am)

Hi,
The 9/32" self tapping screw just wouldn't cut it. I wound up tapping the hole with a 5/16" NC 16 tap bit mounted from a small T bar tap ratchet. I removed a piece of a web from the grill to give me some leverage. Its a very tight area in behind the grill to work with but a threaded bolt and lock washer now has the cooling fan relay firmly re-secured. I think a secure mount might work as a ground for the circuit as well so a tight installation with no loose play is a must. Be careful not to tighten the bolt too hard or you may strip the (2) threads in the hole. Some thread lock might be a good idea as well. The cooling fans are now working once again with a warm engine idling while stopped in traffic !

Replies to this message:

amduncan (Mar 09, 2007 9:20 pm)

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