How to Replace the Compressor in a Dodge Durangoby Chris Moore
The compressor is one of the three major parts of an air-conditioning system. You can replace the compressor on your Dodge Durango's air conditioner, but be aware that working on an air-conditioning system can be dangerous because of the high pressure the system is under and the environmental laws that govern refrigerant. Consult your mechanic before you attempt it. The new compressor and the refrigerant oil used must be compatible with R-134a refrigerant.
Take the Durango to a licensed technician who can properly discharge the air-conditioning system.
Disconnect the truck's negative battery cable.
Remove the air intake duct and resonator. Loosen the duct's hose clamps with a screwdriver to disconnect it, then remove the resonator's mounting bolts and pull it forward from the throttle body.
Take off the drive belt by rotating the belt tensioner to relieve the tension and slipping the belt off the pulley. Some models require a breaker bar and socket to rotate the tensioner, while others require a wrench.
Disconnect the electrical connector to the compressor clutch and the refrigerant lines on the compressor. Plug the open fittings at the lines and discard the O-rings.
Remove the bolts connecting the compressor to its mounting brackets with a wrench and lift the compressor from the vehicle.
Transfer the clutch from the old compressor to the new if the new one does not have a clutch. This will involve a special puller tool from an auto parts store.
Fill the replacement compressor with the correct amount of fresh refrigerant oil; pouring the oil from the old compressor into a graduated container is the best way of finding out the amount it used.
Install the compressor in place on its brackets on the engine and apply the bolts. Connect the refrigerant lines and the electrical connector; use new O-rings made for air-conditioning use and lubricate them with refrigerant oil.
Reconnect the drive belt and the air intake duct and resonator. Reconnect the battery cable.
Return the truck to the same technician to have its AC system evacuated and recharged.
Items you will need
- Breaker bar and socket
- Compressor clutch puller tool
- Refrigerant oil
- "Chilton Dodge Durango/Dakota Repair Manual"; John Wegmann; Haynes North America; 2006
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