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Heater Core Replacement (Finished!!)

92K views 97 replies 19 participants last post by  FSTDANGO3  
#1 ·
Well guys, its that time. Finally got moved into the house and have a garage to work in to tackle this beast of a problem. Here's the previous thread on the topic:
http://durangoclub.com/forum/viewtopic.php?t=2093

Well, after day 2, I have a lot of things removed from the car, but still have a ways to go. Overall have spent about 4.5 hours on it so far. I have tons of pieces in the back seat, and following somebodys advice on here, have been taping the correct screws to the pieces as I take them off so none are lost or misplaced.

The big goal yesterday was the removal of the steering column and wheel, how much fun that was. The biggest pain was the one bolt down at the steering shaft. I could get to it easy and everything, but even after I got the nut broke loose, that thing wouldn't hardly budge with every tiny turn. Ended up taking me an hour to get the bolt off with the rest in-between. Towards the end, I sprayed RemOil on it and then it started to move a lot easier, so I'd recommend doing that from the beginning to anybody attempting this endeavor.

I have also now found supporting evidence of a bad heater core in the form of a stained piece of foam in my driver side vent. I removed it and can see a heavy greenish coating on the backside of it (picture included below.)

The shift cable at the base of the steering column was also not an easy task to remove just because it was hard to figure out how the plastic tabs on the backside were holding it in its bracket. It was two clips that just squeezed flush with the body of the cable, and while flush, pull the cable and it was no problem.

I'm now in the process of removing different connectors under the dash, and am getting ready to remove the center support bracket, and then I'm almost done with getting to the heater A/C housing. I don't think I could have ever done this without the FSM, although even it was a little vague with some of the random harness connectors to be unplugged and where they were, or what they even looked like, or how some of these darn clips everywhere worked. I don't think any two clips holding stuff on are the same. I have seen at least 10 different kinds of clip methods to hold on the plugs and cables.

I'll update later once I get the dash out and get to the heater core. Until then, here are some pics of this fun process :roll:
 

Attachments

#52 ·
That's what I said to my friends,and they laughed at me!! Nobody in their right mind wants to do it flatrate.
 
#53 ·
I spoke to a local mechanic friend of mine and he says he can change out the Heater core and evap in 6 hours on a D Not including recharging the system and refilling coolant system
When asked how since it takes everyone else so long he stated that he has done plenty of them and just has a system down pat
Steve
DOC Pres
 
#54 ·
Yep, when I did mine the first time, it took me 20 hours start to finish. I helped a friend at work change out his heater core and evap, and even recharge it a couple months ago on his 2000 Durango. We were able to do it in 6 hrs flat! It was amazing how much easier it's after you have done it once or twice :)
 
#56 ·
Heck 6 hours you can do that as a layover on the drive to the plant tour!
Steve
DOC Pres
 
#57 ·
LOL It really wasn't that bad, except for the heat, it was 90+ degrees that day out in the sun. Only problem Indy is by the time you spend the gas to come down here you could have paid someone to fix it there heheh.
 
#60 ·
I'm going come along as well
Kind of a SMR reunion install Indys EVAP PARTY!
Steve
DOC Pres
 
#62 ·
Now do you have any Go Karts Near By?
You Know Indy likes to play!
Steve
DOC Pres
 
#63 ·
There's an indoor track at Charleston about 45 minutes away :) Or we could hit up some trails near my house and go off-roading. Another possibility is the small lake they made 5 minutes from my house and shooting range :twisted:
 
#64 ·
OFF ROAD?DO YOU MEAN IN OUR D's??OK I'LL Do It.
Steve
DOC Pres
 
#66 ·
WOW! Willing to get it dirty again? You guys would be in the durangos, I'd be in my Bronco :p. We won't go anywhere too hardcore, just a nice ride and some nice sites.
 
#67 ·
VTengineer said:
WOW! Willing to get it dirty again? You guys would be in the durangos, I'd be in my Bronco :p. We won't go anywhere too hardcore, just a nice ride and some nice sites.
YES I'm willing to get it Dirty!
Steve
DOC Pres
 
#68 ·
LOL, in that case, we GOTTA do this! I'd almost die to see mud up to the top of the windows on the Bronze Beast HAHAHAH :twisted:
 
#69 ·
NOW YOU ARE GETTING SILLY!
TOP OF THE WINDOWS?OK
Steve
DOC Pres
 
#71 ·
Guess its all up to Indy Now!!
Steve
DOC Pres
 
#72 ·
yep! I'm sure he wouldn't mind a little mud :)
 
#73 ·
:? I Dunno he may get those pretty wheels dirty :naughty:
Steve
DOC Pres
 
#74 ·
The wheels are the least of this problems, he'd probably get stuck with those road tires :lol:
 
#75 ·
Yes But all that self proclaimed Power!
Steve
DOC Pres
 
#76 ·
LOL, I showed him who has the most power at the SMR :cheesy:! He never stood a chance mwuhahahaha!