Dodge Durango (HB). Manual — part 1572
NOTE: The connector fitting ends must be posi-
tioned into the counterbore of the jaws in order for
the connector fitting to properly seal the repair
area.
15. Install the connector fitting (1) and the line ends
(4) into the counterbore of the jaws (5).
16. Hold the tool body (Special Tool 8456-3 in Kit
8456-A) (2) with a 3/8 inch breaker bar and turn
the forcing screw (3) clockwise.
NOTE: The lines must be kept fully inserted into
the connector fitting to obtain a leak free joint.
17. Turn the forcing screw (1) clockwise until both
connector fitting collars (2) have bottomed out on
the center shoulder of the connector (3).
18. Loosen the forcing screw and remove the tool
body (Special Tool 8456-3 in Kit 8456-A) (4) and
the jaws (5) from the repaired line(s).
19. Install the underbody mounting brackets as nec-
essary (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING
-
REAR/LINES-
UNDERBODY - INSTALLATION).
20. Lower the vehicle.
21. Reconnect the negative battery cable.
22. If repairing an underbody coolant line, refill the
engine cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE - COOLING SYSTEM
REFILL).
23. If repairing an underbody refrigerant line, evacuate and recharge the refrigerant system (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - FRONT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVAC-
UATE) and (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT - STANDARD PROCEDURE
- REFRIGERANT SYSTEM CHARGE).
UNDERBODY LINE ASSEMBLY
WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT - WARNINGS) and (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING - FRONT - CAUTIONS). Failure to follow the warnings and cau-
tions could result in possible personal injury or death.
HB
PLUMBING - REAR
24 - 481
1. Recover the refrigerant from the refrigerant system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - STANDARD PROCEDURE
- REFRIGERANT SYSTEM RECOVERY).
2. Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOL-
ING SYSTEM DRAIN).
3. Disconnect and isolate the negative battery cable.
4. Raise and support the vehicle.
5. Remove the right front wheelhouse splash shield
(Refer to 23 - BODY/EXTERIOR/LF WHEEL-
HOUSE SPLASH SHIELD - REMOVAL).
6. Remove the secondary retaining clips (2 and 7)
from the refrigerant line couplers (6) located on the
suction line extension tube (5) and the liquid line
extension tube (8).
7. Disconnect the underbody liquid and suction lines
from the liquid line extension tube and the suction
line extension tube and remove and discard the O-ring seals (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING -REAR/COUPLER-REFRIGERANT LINE - REMOVAL).
8. Install plugs in, or tape over the refrigerant line couplers and the underbody refrigerant lines.
9. Disconnect the underbody heater hoses from the front heater hoses.
10. Remove the nut (1) that secures the rear suction
line (2) and the rear liquid line (3) to the rear
evaporator
extension
line
tapping
plate
that
extends through the rear floor panel (4) behind
the right rear wheel housing.
11. Disconnect the rear suction line and liquid line
from the rear evaporator extension line tapping
plate and remove and discard the O-ring seals.
12. Install plugs in, or tape over the opened refriger-
ant lines and tapping plate ports.
13. Disconnect the rear heater hoses (5) from the
rear heater core tubes that extend through the
rear floor panel behind the right rear wheel
housing.
24 - 482
PLUMBING - REAR
HB
14. Remove all body mount bolts on the passenger side of the vehicle and loosen the body mount bolts on the
drivers side.
15. Place a jackstand at the front and rear of the vehicle on the passenger side so that the stands will safely sup-
port the body.
16. Remove the five screws (7) that secure the underbody lines (1) to the vehicle underbody (2).
17. Carefully lower the hoist until the right side of the body (supported by the stands) is approximately 76-101 mm
(3-4 in.) above the frame. This will gain access to remove the underbody line assembly.
18. Remove the underbody line assembly from the underneath of the vehicle body.
INSTALLATION
1. Position the underbody line assembly underneath the vehicle body.
2. Carefully raise the hoist until the frame and body mounts line up together.
HB
PLUMBING - REAR
24 - 483
3. Install the five screws that secure the underbody lines (1) to the vehicle underbody (2).
4. Install all body mount bolts to the passenger side of the vehicle. Tighten all passenger and driver side mount
bolts securely.
5. Raise the hoist and remove the jack stands from under the vehicle.
6. Connect the rear heater hoses (5) to the rear
heater core tubes that extend through the rear floor
panel (4) behind the right rear wheel housing and
install the heater hose clamps.
7. Remove the tape or plugs from fittings on the rear
suction line (2) and the rear liquid line (3) and the
rear evaporator extension line tapping plate ports.
8. Lubricate new rubber O-ring seals with clean refrig-
erant oil and install them onto the rear suction and
liquid line fittings. Use only the specified O-rings as
they are made of a special material for the R-134a
refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.
9. Connect the rear suction and liquid line fittings to
the rear evaporator extension line tapping plate.
10. Install the nut (1) that secures the rear suction
and liquid lines to the rear evaporator extension
line tapping plate. Tighten the nut to 23 N·m (17
ft. lbs.).
11. Connect the underbody heater hoses to the front
heater hoses and install the heater hose clamps.
12. Remove the tape or plugs from the refrigerant line
couplers (6) and the underbody refrigerant lines.
13. Lubricate a new rubber O-ring seal with clean
refrigerant oil and install them onto the refrigerant
line couplers. Use only the specified O-ring as it is
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended
for the A/C compressor in the vehicle.
14. Connect the underbody liquid and suction lines to
the liquid line extension tube (8) and the suction
line extension tube (5) (Refer to 24 - HEATING &
AIR
CONDITIONING/PLUMBING/COUPLER-RE-
FRIGERANT LINE - INSTALLATION).
15. Install the secondary retaining clips (2 and 7) onto
the refrigerant line couplers.
16. Install passenger side tires (Refer to 22 - TIRES/
WHEELS/WHEELS - STANDARD PROCEDURE).
17. Install the right front wheelhouse splash shield (Refer to 23 - BODY/EXTERIOR/LF WHEELHOUSE SPLASH
SHIELD - INSTALLATION).
18. Lower the vehicle.
19. Reconnect the negative battery cable.
20. Fill the engine cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE - COOLING SYSTEM FILL).
21. Evacuate the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT - STAN-
DARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
24 - 484
PLUMBING - REAR
HB
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