Do i need special tools to replace a leaky radiator on my 2002 5.9l D ?. Easy to do?.
Thanks.

 

My 99 only needed pliers(for hose clamps), an 8mm socket (for the rad to core support bolts), and a large wrench to take your fan off. I know your shroud is different than mine but it took either a 12 or 13mm socket to get it off. Honestly you might even be able to hang your shroud off of the fan and sneak the rad out without taking the fan off. If you have the Trans cooler in your rad then you will need to take them off as well.


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But keep a blow torch and mallet nearby if its as feisty as my 2000

 

You may need a line lock tool similar to fuel injection lines depending on the type of transmission cooling lines. The tools are cheap at chain stores and very easy to use.

If you're replacing the radiator, use this opportunity to completely flush the engine and heater core.

 

how do you get the a/c condenser which is hooked to the radiator off? do you need to
to remove the bumper for that?.Also what size wrench do you need to remove the transmission cooler lines ?. Thanks

 

On mine the stock cooler lines take a 3/4 for the top and 5/8 for the bottom, the replacement lines take a 3/4 for the top and 11/16 for the bottom. So depending on weather or not they have been replaced or not you will need 2 of those 3 sizes. To be honest its been about 3 years since i have had a/c so i don't recall how the condenser went on. I remember there being 2 tabs on the front of the upper core support but not any others. I had a tree run out in front of me so i had my bumper off to fix it anyways. It seems to me that you wouldn't need to take it off.


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You should not need to remove the A/C condenser to remove the radiator as that would require discharging the system and using a special tool to break the lines apart...


RADIATOR REMOVAL

(1) Disconnect battery negative cable.

WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAINCOCK
WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.

(2) Drain cooling system.

(3) Remove fan shroud retaining hardware.

(4) Position fan shroud towards engine. Fan
shroud does not have to be removed from vehicle.

(5) Disconnect transmission cooler lines at radiator. Use quick connect fitting release tool#6935.


WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CONSTANT
TENSION CLAMPS.

CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter.

(6) Remove upper and lower radiator hose clamps and hoses at radiator.

(7) Remove two upper radiator-to-radiator support
bolts. The radiator has two alignment pins
to align lower part of radiator to lower radiator support.

(8) Lift radiator up and out of engine compartment.
Do not allow cooling fins of radiator to contact
any other vehicle component. Radiator fin damage
could result.

(9) Remove transmission auxiliary cooler (if equipped).

 

Sorry i think my truck is different from what you are describing!

 

that breakdown is out of the CHRYSLER ISSUED service manual that the dealer uses to work on all 2002 Model year Durangos, it IS correct