How To: Thermostat R&R - Chevy and GMC Duramax Diesel Forum
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Old 02-15-2011, 07:29 PM   eBay Motors  #1 (permalink)
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How To: Thermostat R&R

How to remove and replace your thermostats. This was done on my '02 LB7 after my Attitude monitor never would get above 145* under normal driving conditions. I soon found out why. Now she runs at 180*-187* with some play time thrown in and my mpg's has actually improved as well. This was my first time on a diesel so bear with me haha.

What you will need:

Ratchett
3" extension (I used a 6. It was easier)
12mm socket
1gal of coolant
About 25 minutes.

Step 1: Remove resonator (big black plastic thing that says duramax 6.6 on it)

Step 2: Locate thermostat housing. It's towards the front of the motor in the middle. Real easy to get to.


Step 3: Remove these bolts.


I ended up taking the back one and front bleeder off which in the end wasnt necessary.



Step 4: Remove 2 bolts holding radiator hose in place. The green circle is a hidden bolt on the other side under the plug-in wires.



Step 5: Lift the top of the housing out of the way so that you can change the thermostats out. PLEASE DONT GET THESE MIXED UP. As you can see, I just set mine up on the closest bolt.



Swap the stats out and do everything in the reverse order to put it back together. DO NOT OVERTIGHTEN BOLTS. Not sure what the torque specs are
but if its not leaking, its tight enough.

Fill to the proper level with coolant and let the motor idle to operating temp. Run it down the road and back if you want. Let it cool. If you have air in the system, unscrew the bleeder screw a little bit til fluid comes out and squeeze on the hose. Check the fluid again, add if necessary.

Sorry this is so shitty, but I've had the flu the past week and was running a temp when I was doing this. If you have any questions, feel free to ask someone else who can better answer them for you. Good day...
-CW
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Old 02-22-2011, 06:48 PM   eBay Motors  #2 (permalink)
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nice write up!
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Old 02-23-2011, 06:51 AM   eBay Motors  #3 (permalink)
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nice write up!
Yeah I forgot the part about checking the dump tank and adding more fluid a day or 2 later if it needs it. Everything worked fine though. No leaks or problems and fuel mileage is showing it's running more efficiently.
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Old 02-23-2011, 09:51 AM   eBay Motors  #4 (permalink)
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Thanks for the info....
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Old 12-10-2011, 09:51 AM   eBay Motors  #5 (permalink)
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Originally Posted by BoostJunky View Post
DO NOT OVERTIGHTEN BOLTS. Not sure what the torque specs are but if its not leaking, its tight enough.

Good writeup for sure. I just had to change out mine (temp stayed around 160 degrees on the highway).
It definitely made a difference in my MPG after too so if your engine isn't getting up to temp, replace them both.

The torque on the Thermostat Cover Bolts is 18 ft-lbs
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Old 02-04-2013, 05:50 PM   eBay Motors  #6 (permalink)
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Thanks, a few questions though,
1) how long did it take you? and
2) are the 2 thermostats the same PN or are they different?
I think that have to do mine this spring, as the coolant temp sometimes climbs up to 115 on a hill ( hot summer day) , then drops back to 100 ( when still climbing). Seems like one may be sticky?

Don
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Old 02-04-2013, 06:14 PM   eBay Motors  #7 (permalink)
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Old 02-04-2013, 10:13 PM   eBay Motors  #8 (permalink)
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Quote:
Originally Posted by Diesel Don View Post
Thanks, a few questions though,
1) how long did it take you? and
2) are the 2 thermostats the same PN or are they different?
I think that have to do mine this spring, as the coolant temp sometimes climbs up to 115 on a hill ( hot summer day) , then drops back to 100 ( when still climbing). Seems like one may be sticky?

Don
Theyre definitely two different stats. I believe one is a 180*F and the other is 185*F
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Old 02-05-2013, 04:29 AM   eBay Motors  #9 (permalink)
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Quote:
Originally Posted by Diesel Don View Post
Thanks, a few questions though,
1) how long did it take you? and
2) are the 2 thermostats the same PN or are they different?
I think that have to do mine this spring, as the coolant temp sometimes climbs up to 115 on a hill ( hot summer day) , then drops back to 100 ( when still climbing). Seems like one may be sticky?

Don

Don, just a few things that might help.

1) Longest part is refilling and bleeding the cooling system (make sure to use the bolt on the thermostat housing to bleed any air out)
2) Definitely 2 different thermostats, one is 80C and the other is 85C (they are metric temps)

Make sure you look into a better tranny cooler (PPE or Mike L work very well) as it helps remove load from the cooling system too.

This video should help too.
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Old 02-08-2013, 03:26 AM   eBay Motors  #10 (permalink)
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Great write ups and video too guys....thanks this is a help.

Is there a specific replacement cycle for these thermostats or is it a preventative measure for the most part. It sounds as though when they fail they remain open from one of the posts above?
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