This procedure covers the replacement of the cooling fan relay in the Power Distribution Center (PDC) located in the engine compartment.

Warnings

Tools required

Parts

• Cooling fan relay × 1 — Use OEM specification (Mopar 68028458AA or equivalent)

Preparation

1. Park vehicle on level surface and turn off ignition
2. Allow engine to cool completely
3. Locate the Power Distribution Center (PDC) on the driver side of engine compartment near the firewall
4. Have replacement relay available and verify correct part number against relay cover diagram

Procedure

1. 1

   Open Power Distribution Center cover
   Release the cover latches on the PDC using a flathead screwdriver or your fingers. The cover has two or three snap latches depending on model year. Lift the cover upward and away to expose the relays and fuses inside.
2. 2

   Identify cooling fan relay location
   Examine the relay diagram printed on the underside of the PDC cover or on the PDC itself. The cooling fan relay is typically labeled 'RAD FAN' or 'RADIATOR FAN RELAY' and is usually a mini relay (not a standard size relay). Note the exact cavity number for your specific vehicle configuration as some models have multiple fan relays.
3. 3

   Remove old cooling fan relay
   Grasp the relay firmly and pull straight upward with steady pressure to remove it from its socket. If the relay is difficult to remove, use needle nose pliers or a relay puller tool, gripping the relay body (not the terminals). Rock gently side-to-side while pulling upward if needed.
4. 4

   Inspect relay socket and terminals
   Examine the relay socket in the PDC for any signs of corrosion, melting, discoloration, or damage to the terminals. If terminals appear corroded, clean gently with electrical contact cleaner. If socket shows heat damage or melted plastic, the entire PDC may require replacement.
5. 5

   Install new cooling fan relay
   Align the new relay with the socket, ensuring the relay tabs or orientation features match the socket configuration. Push the relay straight down into the socket with firm, even pressure until it is fully seated. The relay should sit flush with surrounding relays and be firmly locked in place.
6. 6

   Close Power Distribution Center cover
   Position the PDC cover over the fuse box, aligning it properly. Press down on all latch points until the cover snaps securely into place. Ensure the cover is fully seated and latches are engaged to prevent moisture intrusion.

Reassembly

1. Ensure PDC cover is properly latched and sealed
2. Verify no tools or parts were left in engine compartment

Verification

• Start the engine and allow it to reach operating temperature to verify cooling fan operation
• Observe that the cooling fan activates when coolant temperature reaches normal operating range (typically 215-220°F)
• With engine running and A/C on, verify that cooling fan activates at high speed
• Check for any unusual noises or fault codes related to cooling system
• Confirm no warning lights are illuminated on instrument cluster

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