Flex-a-Lite 57291 Radiator & Fan GM Truck/SUV - Manual (Page 2)

Detail 1
Detail 2
the plastic factory hose clamp to this bracket then connect the larger upper inlet hose to the driver
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.
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