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Keep in mind I've not successfully converted a Dodge Dakota yet, but I have successfully converted several Chevy trucks and SUVs.
On the fan, you can't beat an OEM. The 2016 Durango radiator is pretty close in dimensions to the 1997-2003 Dakota radiator, so the electric fan for a 2016 Durango should be close enough to use with minimal modification. The 2016 V8 core size is 25.44 inches wide x 18.81 inches tall while the 2nd gen Dakota is 23.438 inches wide by 18.688 inches tall. This is how I would be doing it if I were keeping the 3.9L in mine, but I'm going to have a wee bit more to cool with mine. I don't know if there's a difference on the fans, but I would get the 2016 5.7L cooling fan. I would also look at a larger alternator for this, because an electric fan can add as much as 40 amps to your electrical load at idle. This balances out with airflow over 45MPH being more than enough to keep the engine cool, so the fans usually won't run at highway speeds unless the AC is on.
I've also had excellent luck using a Delta Control unit to run fans. What I like about this controller is it constantly measures the coolant temp on the radiator and will speed up or slow down the fan to maintain a constant temp, and when it kicks on it is a soft start so it doesn't shock the electrical system. This controller is also able to handle turning the fans on when the AC compressor is operating, which is very important if you want to run the air conditioner. The truck already has a supplemental electric fan on it, and this controller might be able to control a larger one, but this would require more investigation.
On the gaskets, I like Felpro and Ultra Copper silicone.
Quick update. Worked the past 3 nights and got both engines pulled. the 97 (that ran) is NASTY. Tons of buildup, sludge, etc. I should've taken a few pics, but it was close to 1am when we got it out, so yeah.
Now it's the process of getting the engine cleaned up as much as possible. I got a handful of products to help. We put a motor flush in the engine and ran it a bit before we pulled it in to take it out. It appears to have helped some, but the buildup is significant (are hard like a cracking, dry, rust feeling in many spots). I also got some Lucas Oil stabilizer and Marvel Mystery oil. Those are going to be saved for down the road, after a manual deep clean.
QUESTION: What should I use to help break down the buildup in the valves/heads? That's where is by far the worst. Can I use Gunk Engine Degreaser? It looks like a good product, but I've only seen it use for general engine bay cleaning, not necessarily after someone removes the valve covers.
I would be tempted to tear it down, and send it to a machine shop for cleaning/checking.....
Unfortunately that's not in the time or money budget for this project. Working on it from 8pm to Midnight each night with goal of finished by next week.
Think I may use the Gunk degreaser and then follow it up with something that flashes off and drys quicker to get the degreaser off, finally finish with coating in some oil. May be a horrible idea, haha, I don't know.
Another quick update. I called GUNK directly. General customer service sent me to the technical department. Talked to an Alan Price. Turns out he's actually one of the formulators that designs the products! We had a great discussion.
He validated that I can use the Engine Degreaser on the valves and other internals. He noted for some trickier surfaces, the Gel aerosol is good so it can sit on it and break down the buildup. The Original formula is stronger than the gel, so where te liquid will soak, best to use that. Then follow up with instant parts cleaner for a quick flash off clean. Dude was super helpful, and we even chatted a bit about all the health concerns etc. that makes it so we have to use 3 products now instead of the one product when I was growing up that was stronger enough to do everything. He finished the call with giving me his direct line for any additional questions I may run into. Customer service done right! In less than 10 minutes, they won a customer for life.
The engine swap is officially complete. Starts and runs well. Still have a list of little things to do.
A couple are shift/drive cable. Right now we have to pull cables under the dash to shift and the 97 is not compatible. Another is speedometer. And also be nice to get new seats.
Anyone know if a drive/shift cable from a 03 durango with a 5.9 will work? Same with seats? I assume they should
