Durango, 2001-2005

Removal & Installation

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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 contact tension clamps.

  1. Locate the thermostat. This is located in a housing on the engine side of the upper radiator hose for the 5.7L and 5.9L engines. On the 3.7L and 4.7L engines, the thermostat is located on the engine side of the lower radiator hose.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant from the block until the level is below the thermostat.
  6.  
  7. On most V-6 and V-8 models the alternator must be removed or repositioned for access to the thermostat housing.
  8.  
  9. Remove the radiator hose from the thermostat housing.
  10.  
  11. Disconnect any sensors fitted to the thermostat housing.
  12.  
  13. Remove the retaining bolts from the thermostat housing. Note lengths of each for ease of installation.
  14.  
  15. Remove the thermostat housing, thermostat, and gasket, if fitted.
  16.  
  17. Note the relative positions of all components, especially gaskets and seals. Note the orientation of the thermostat in the housing.

    Click image to see an enlarged view

    Fig. Safe removal of constant tension clamps requires the proper tool

    Safe removal of constant tension clamps requires the proper tool

    Click image to see an enlarged view

    Fig. On 5.7L and 5.9L engines, the gasket goes above the thermostat

    On 5.7L and 5.9L engines, the gasket goes above the thermostat

    Click image to see an enlarged view

    Fig. On the 3.7L and 4.7L engine, the thermostat is at the bottom of the engine

    On the 3.7L and 4.7L engine, the thermostat is at the bottom of the engine

    Click image to see an enlarged view

    Fig. Removing the thermostat from the manifold-typical

    Removing the thermostat from the manifold-typical

    Click image to see an enlarged view

    Fig. A bit of paper towel will keep the bolt in the socket until the bolt hole is reached

    A bit of paper towel will keep the bolt in the socket until the bolt hole is reached
  18.  

To install:

  1. Be sure the new thermostat is the correct one for your engine.
  2.  
  3. Clean the gasket or seal mating surfaces.
  4.  
  5. Paper gaskets must be replaced.
  6.  
  7. Install the thermostat, gasket or seals.
  8.  
  9. Install the thermostat housing on the engine.
    NOTE
    The thermostat housing may have the word the word FRONT stamped on housing (5.7L, 5.9L engines). For adequate clearance, this must be placed towards the front of the vehicle; the housing is slightly angled forward.

  10.  
  11. Be sure all components are properly seated before tightening.
  12.  
  13. Tighten the housing bolts to 18 ft. lbs. (24 Nm). Fasteners should be tightened evenly to avoid leaks or damage.
  14.  
  15. Reinstall the radiator hose onto the housing.
    NOTE
    Ensure that you have secured the system drain plug(s) before refilling with coolant.

  16.  
  17. Refill the radiator with a proper coolant mixture.
  18.  
  19. Connect the negative battery cable(s).
  20.  
  21. Start the engine and bleed the cooling system. Refer to "General Information And Maintenance".
  22.  
  23. Ensure that the thermostat is operational (by checking the upper radiator hose for warmth), and that there are no leaks.
  24.  

 
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