Aspen 2007, Durango 2006-2007

Removal & Installation

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3.7L & 4.7L Engines



  1. Disconnect the battery negative cable.
  2.  
  3. Drain the radiator.
  4.  
  5. Remove any cables or lines clipped to the radiator or shrouds.
  6.  
  7. Remove the upper and lower heater hoses.
    WARNING
    Most cooling system hoses use "constant tension" hose clamps. When removing or installing, use a tool designed for servicing this type of clamp. The clamps are stamped with a letter or number on the tongue. If replacement is necessary, use only an OEM clamp with a matching ID.


    CAUTION
    Always wear safety glasses when servicing constant tension clamps.

  8.  
  9. If coolant overflow and windshield washer fluid bottles are fitted to the fan shroud, disconnect the lines and remove them. Pull straight up to remove the bottles from shroud.
  10.  
  11. On 3.7L and 4.7 models, remove the upper fan shroud. Disconnect the electric fan wiring.
  12.  
  13. Remove the fan shroud hardware and reposition the shroud towards the engine for access to the radiator.
  14.  
  15. Label, then disconnect the automatic transmission lines if the fluid cooler is incorporated into the radiator. Plug the lines to prevent spillage. Be sure to note which line goes to which fitting.
  16.  
  17. Check for rubber shields on the sides of the radiator. Remove them if fitted. These are normally secured with non-reusable plastic pins.
  18.  
  19. Remove the radiator bolts (usually two at the top). Lift the radiator up and out of the vehicle, being careful that the cooling fins do not bang against anything. They are easily damaged.
  20.  
  21. Some vehicles may have an auxiliary automatic transmission fluid cooler which will come away with the radiator.

    Click image to see an enlarged view

    Fig. Size marking on constant tension clamps (1)



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    Fig. Coolant bottle T-slots and studs



    Click image to see an enlarged view

    Fig. Shroud assembly (4.7L): Radiator (1), Fan (2), Upper Shroud (3), Bolts (4), Lower Shroud (5).



    Click image to see an enlarged view

    Fig. Mark automatic transmission oil cooler lines before disconnecting. Supply (1) and return (2) lines in this illustration for the 4.7L engine



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    Fig. Plug the transmission lines to prevent leakage



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    Fig. Radiator mounting bolt

  22.  

To install:

  1. Lower the radiator into place. There are two alignment pins at the bottom which fit into holes in the lower support.
  2.  
  3. Tighten radiator mounting bolts to 17 ft. lbs. (23 Nm).
  4.  
  5. The remainder of the procedure is the reverse of removal. Double-check the connection of all hoses and lines before adding fluids or operating the vehicle.
  6.  

5.7L Engine



  1. Disconnect the battery negative cable.
  2.  
  3. Drain the radiator.
  4.  
  5. Remove any cables or lines clipped to the radiator or shrouds.
  6.  
  7. Remove pushpins and the upper condenser/radiator seal.

    Click image to see an enlarged view

    Fig. Upper radiator/condenser seal

  8.  
  9. Remove air filer housing assembly.
  10.  
  11. Remove upper radiator hose.
  12.  
  13. Remove overflow tube.
  14.  
  15. Remove radiator fan shroud from the radiator and position over the radiator fan.
  16.  
  17. Remove the upper radiator support.
  18.  
  19. Raise vehicle.
  20.  
  21. Disconnect the power steering cooler lines.
  22.  
  23. Disconnect the transmission cooler lines.
  24.  
  25. Remove the lower radiator hose.
  26.  
  27. Lower vehicle.
  28.  
  29. Remove upper radiator mount.
  30.  
  31. Remove LH and RH radiator side seals.
  32.  
  33. Remove radiator.
  34.  
  35. Remove power steering cooler form the radiator, if necessary.
  36.  
  37. Remove transmission cooler from radiator, if necessary.
  38.  

To install:

  1. Install power steering cooler, if removed.
  2.  
  3. Install transmission oil cooler, if removed.
  4.  
  5. Install the upper radiator mount
  6.  
  7. Position isolator pins into alignment holes in radiator lower support.
    NOTE
    The radiator has two isolator pins on bottom of both tanks. These fit into alignment holes in radiator lower support.

  8.  
  9. Install upper radiator support. Tighten bolts to 200 inch lbs. (23 Nm).
  10.  
  11. Install LH and RH radiator side seals.
  12.  
  13. Install upper radiator hose.
  14.  
  15. Install overflow tube.
  16.  
  17. Install radiator shroud.
  18.  
  19. Raise vehicle.
  20.  
  21. Install power steering cooler lines.
  22.  
  23. Install transmission cooler lines.
  24.  
  25. Install lower radiator hose.
  26.  
  27. Lower vehicle.
  28.  
  29. Install air filter housing assembly.
  30.  
  31. Install upper radiator/condenser seal.
  32.  
  33. Fill radiator.
  34.  
  35. Connect battery negative cable.
  36.  
  37. Start and warm the engine; check for leaks.
  38.  

 
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