OEM 2004 Dodge Durango Piston

2004 Dodge Durango Piston Parts and Q&A

• Q: How to Remove and Replace a Piston and Its Connecting Rod on 2004 Dodge Durango?

  A: For piston and connecting rod replacement, start by pulling out the negative cable from the battery, removing the oil pan and gasket/windage tray and removing the cylinder head(s). If removal of the cylinder ridge is needed, use a ridge reamer and cover the pistons as you do so. With the crankshaft turned to center each rod in the cylinder bore, take out the piston and connecting rod assemblies at the top of the engine. Avoiding number stamping or punching the rods and caps helps protect them from being damaged, but I recommend marking their positions with a permanent ink marker or scribe tool and making sure you don't harm the broken joints. Wrest the connecting rod cap off, put on Special Tool 8507 Connecting Rod Guides, remove the piston from its bore and do this for all the connecting rods. As soon as you separate the piston from its connecting rod, fit the bearing cap there to protect the rod. Clean each piston with a fitting cleaning solvent and warm water afterward, let it dry with a towel and then use a scraper, ensuring you do not take out the piston pin from the assembly. Check if the connecting rod journal has too much wear, if the rod shows signs of bending or twisting and watch out for cracks or damage to the ring lands, piston taper, elliptical shape and scoring. Set up the piston rings inside the cylinder first and then dip the piston head and rings in oil, slipping a ring compressor over them and gently tightening the device while keeping the rings where they are. Put the connecting rod and the bearing pin together, lubricate the bearing and insert Bolt Guide Rings Special Tool 8507 into the connecting rod hole. Be sure the raised F on the piston pin bore is facing the front of the engine and the connecting rod oil slinger slot is also turned that way. Coat the cylinder bore with oil, move the crankshaft so the connecting rod is properly positioned and slide the rod and its piston into the bore until the connecting rod is centered on the journal. Bear in mind that these bolts are torque to yield bolts, so use new bolts each time you remove and replace them. Add engine oil to each rod bolt and the bearing surfaces, fit the connecting rod cap and bearing and tighten all bolts to 27 Nm (20 ft. lbs.) plus 90°. After that, put back the cylinder head(s), timing chain, covers, oil pan and gasket/windage tray, place just the proper engine oil in the crankcase and link the negative cable to the battery.