Recently bought a 2000 with a 5.9 and a 6 speed that took some hits on the way to the auction.

Front bumper has to come off and the rad is toast as well. Wanted to ask if anyone has suggestions on what to take care of when I pull the rad and the lower rad support. Should I take off timing cover and redo gasket? Kdp? Fan clutch? Should probably test intercooler as well but haven’t looked at how to pressurize it with air.

What else?

In the meantime my other 2nd gen has a front hub that’s so frozen that a 6lb sledge is doing nothing. I’m smacking it so hard I might new ball joints and tre. No bueno. Remember your anti seize.

 

There is a quick fix for the KDP, (well, once you can get down to it.) Simple bolt in. XDP makes one. (though I have no clue who they are.....)

No idea how to test the intercooler... Give it close inspection, as I suspect you are going to have it out anyway???

 

Easy way to test intercooler; plug air outlet from the cooler, make some sort of adapter to the inlet end for to use pressurized air through the regulator. 40 psi should be enough.
If it's cracked, you'll hear the air hissing through.

You can make the adapter and plug from thick piece of plywood for example, and mount them to the rubber boots that are already on the intercooler. And you probably can get away just drilling tight hole for the air gun to apply air in to the cooler, so the regulator is not necessary.