🔧 Journey - Thermostat Replacement

The thermostat controls coolant flow to keep your engine at the correct temperature. If it sticks closed you can overheat; if it sticks open the engine may run cold and set a check-engine light. On your Journey, the thermostat is part of a housing at the engine-side end of the lower radiator hose.

Difficulty Level: Intermediate | Estimated Time: 1.5-3.0 hours

Assumption: Thermostat is serviced as a thermostat housing assembly (common on the 2.4L).

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⚠️ Safety & Precautions

• ⚠️ Never open the coolant cap on a hot engine; wait until fully cool.
• ⚠️ Coolant is toxic—keep it off skin/eyes and away from pets.
• ⚠️ Electric cooling fans can turn on by themselves; keep hands/tools clear.
• ⚠️ Support the vehicle with jack stands if you lift it—never rely on a jack.
• 🔋 Battery disconnect is not required, but it’s OK to disconnect the negative cable if you want extra safety around the fans.

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🔧 Required Tools

You'll need the following tools for this repair:

• Safety glasses
• Nitrile gloves
• Wheel chocks
• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• Drain pan (at least 10-quart)
• Funnel
• Spill-free funnel kit (specialty)
• Shop rags
• 8mm socket
• 10mm socket
• 1/4" drive ratchet
• 3" and 6" 1/4" drive extensions
• Hose clamp pliers (specialty)
• Trim clip remover
• Torque wrench (inch-pound)

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Thermostat housing assembly (with thermostat) - Qty: 1
• Thermostat housing gasket / O-ring - Qty: 1
• Engine coolant (Mopar OAT 50/50 premix, purple) - Qty: 1-2 gallons
• Hose clamp (lower radiator hose) - Qty: 1 (replace if weak/damaged)

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📋 Before You Begin

• Park on level ground, set the parking brake, and chock the rear wheels.
• Let the engine cool completely (radiator hose should feel cool).
• Set your heater to full HOT later during bleeding (this helps move coolant through the heater core).
• Place a drain pan under the radiator area before you open anything.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Relieve pressure safely

• Put on safety glasses and nitrile gloves.
• Slowly loosen the coolant reservoir cap by hand to release any leftover pressure, then remove it.

Step 2: Raise the front (if you need more access)

• Place wheel chocks behind the rear tires.
• Use a floor jack (rated 3-ton minimum) to lift the front at the proper jacking point.
• Set the vehicle down onto jack stands (rated 3-ton minimum).

Step 3: Drain enough coolant to get below thermostat level

• Position a drain pan (at least 10-quart) under the radiator drain area.
• If equipped with an access shield, remove fasteners using a trim clip remover and/or 10mm socket.
• Drain coolant from the radiator drain cock (if accessible). If the drain cock isn’t accessible, you can drain by carefully removing the lower radiator hose in Step 5 (expect a faster gush).

Step 4: Locate the thermostat housing

• Follow the lower radiator hose to the engine. The hose connects to the thermostat housing.
• Use a shop rag to wipe the area clean so dirt can’t fall into the opening.

Step 5: Remove the lower radiator hose from the thermostat housing

• Use hose clamp pliers (specialty) (they lock onto spring clamps) to compress the clamp and slide it back on the hose.
• Twist the hose by hand to break it loose, then pull it off the housing.
• Let coolant drain into the drain pan.
• Tip: Twisting first prevents tearing the hose.

Step 6: Remove the thermostat housing

• Remove any obstructing components as needed using a 10mm socket and 1/4" drive ratchet.
• Remove thermostat housing bolts using an 8mm socket (some fasteners may be 10mm depending on housing design).
• Pull the thermostat housing straight off and keep the opening facing up to reduce spills.

Step 7: Clean the sealing surfaces

• Remove the old gasket / O-ring.
• Use a shop rag to clean the mating surfaces until dry and smooth.
• Do not gouge the aluminum surface.

Step 8: Install the new thermostat housing

• Install the new gasket / O-ring onto the new housing (make sure it sits flat and is not twisted).
• Position the new thermostat housing and start all bolts by hand to avoid cross-threading.
• Tighten bolts evenly using an 8mm socket and 1/4" drive ratchet.
• Final-tighten using a torque wrench (inch-pound): Torque to 12 N·m (106 in-lbs).

Step 9: Reinstall the lower radiator hose

• Slide the hose fully onto the thermostat housing.
• Use hose clamp pliers (specialty) to move the clamp back into its original position.
• If the clamp feels weak or won’t hold tension, replace it.

Step 10: Refill coolant and bleed air

• Install a spill-free funnel kit (specialty) onto the coolant reservoir opening, then add Mopar OAT 50/50 premix using a funnel as needed.
• Start the engine and set the HVAC to full HOT.
• Let the engine idle until it reaches normal operating temperature. Watch for heat from the vents.
• As the thermostat opens, the coolant level may drop—add coolant as needed.
• Gently squeeze the upper radiator hose a few times to help push trapped air out (use nitrile gloves).
• Once bubbles stop and heat is steady, shut the engine off and let it cool completely, then top off to the FULL COLD mark.

Step 11: Reinstall shields and lower the vehicle

• Reinstall any shields using a trim clip remover and 10mm socket.
• Raise slightly with the floor jack, remove jack stands, then lower the vehicle.

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✅ After Repair

• Start the engine and check carefully for leaks around the thermostat housing and the lower hose connection.
• Confirm the heater blows hot and the temperature gauge stays normal.
• After your first drive and a full cool-down, recheck the coolant level and top off to FULL COLD.
• If the check-engine light was on, it may take a few drive cycles to clear; a scan tool can clear codes immediately.

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💰 DIY vs Shop Cost

Shop Cost: $350-$650 (parts + labor)

DIY Cost: $60-$140 (parts only)

You Save: $210-$590 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1.5-3.0 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.