Dodge Durango 2017-2024 Engine Intake Manifold Gasket Set Replacement Guide
Fix rough idling, check engine lights, and leaks by choosing the right intake gaskets for your Durango's engine.
- Symptoms usually point to a vacuum leak (rough idle, lean codes P0171/P0174) or a coolant leak (overheating, sweet smell).
- For the 3.6L V6, always replace the upper plenum gaskets when changing spark plugs to prevent future leaks.
- Check for TSB 09-012-24 if you have a 2022-2023 5.7L model with a cylinder 1 misfire, as the manifold itself may be cracked.
- Fel-Pro and Victor Reinz are top-tier aftermarket brands that offer OEM-quality seals for this repair.
Is Your Durango's Intake Gasket Failing?
A bad intake manifold gasket can cause a range of frustrating issues. The symptoms usually point to either a vacuum leak (too much air) or a coolant leak. Knowing the difference helps you diagnose the problem correctly.
Symptoms of a Vacuum Leak:
- Rough or Unstable Idle: Your engine may shake or vibrate at a stop, and the RPMs might fluctuate.
- Check Engine Light: The most common codes are P0171 and P0174, which mean the engine is running too lean (too much air). You might also see a general misfire code like P0300.
- Hissing or Whistling Sound: You may hear a distinct sucking or hissing noise from the engine bay, which is air being pulled through the broken gasket seal.
- Poor Performance & Fuel Economy: The incorrect air-fuel mixture reduces power and makes the engine burn more fuel to compensate.
Symptoms of a Coolant Leak:
- Engine Overheating: Losing coolant will cause your engine temperature to climb, especially under load.
- Visible Coolant Leak: You might see coolant dripping from the top of the engine, running down the sides.
- Sweet Smell: The smell of burning coolant is a classic sign of an external leak hitting hot engine parts.
- White Exhaust Smoke: If the gasket leaks internally, coolant can enter the combustion chamber and burn off as white smoke.
- Milky Engine Oil: A severe internal leak can allow coolant to mix with your engine oil, turning it into a milky, frothy substance. This is a critical issue that can destroy your engine.
Known Issue: 2022-2023 Durango 5.7L Cracked Intake Manifold
Dodge issued Technical Service Bulletin (TSB) 09-012-24 for some 2022-2023 Dodge Durangos with the 5.7L HEMI engine. The issue is a fracture crack on the intake manifold itself, not just the gasket. Symptoms include a Check Engine Light for a cylinder 1 misfire (P0301), rough idle, and shaking while driving. If you have these specific symptoms, the intake manifold may need to be inspected and replaced, not just the gaskets.
Choosing the Right Aftermarket Gasket Set
For a daily-driven Durango, you don't need to overspend, but quality is critical for a long-lasting seal. OEM Mopar gaskets are a reliable choice, but top-tier aftermarket brands offer similar or better quality, often at a better price.
- Tier 1: Fel-Pro & Victor Reinz
Both Fel-Pro and Victor Reinz are highly respected brands that meet or exceed OEM quality. Fel-Pro is known for designing gaskets specifically for the repair environment, meaning they help seal surfaces that may not be perfectly flat after years of use. Victor Reinz is an OEM supplier for many manufacturers and is known for its high-quality, pliable materials. You can't go wrong with either brand for a stock Durango. - Tier 2: Cometic Gasket
Cometic is a premium brand known for high-performance and racing applications. They often use advanced materials and offer gaskets in different thicknesses for custom engine builds. While excellent quality, a Cometic gasket is likely overkill for a standard Durango that hasn't been modified with a supercharger or turbo.
Pro Tip for 3.6L Pentastar V6 Owners
The 3.6L engine has a two-piece intake manifold with upper (plenum) and lower gaskets. To change the spark plugs on the passenger side, the upper intake manifold must be removed. It is highly recommended to replace the six upper intake plenum gaskets (Mopar Part #5184562AC or aftermarket equivalent) anytime you do a spark plug job to prevent future vacuum leaks.
Cost to Replace Dodge Durango Intake Manifold Gaskets
The total cost depends on your engine and local labor rates. The job is more complex on the 3.6L V6 than on the 5.7L or 6.4L HEMI engines due to the two-piece manifold design.
| Part/Service | Estimated Cost |
|---|---|
| New Aftermarket Gasket Set | $20 - $71 |
| New OEM (Mopar) Gasket Set | $35 - $85 |
| Shop Labor | $250 - $500 |
| Total Estimated Cost | $270 - $585 |
Cost estimates are approximate and can vary based on your vehicle's engine, your location, and the repair shop.
Frequently Asked Questions
Which gaskets do I need for my 3.6L V6?
The 3.6L Pentastar engine uses two sets of gaskets. The 'upper' or 'plenum' gaskets seal the plastic upper manifold. The 'lower' gaskets seal the lower manifold to the cylinder heads. If you are just changing spark plugs, you only need the upper set. If you have a confirmed leak from the lower gaskets, you should replace both sets at the same time.
Do I need to use RTV sealant with the new gaskets?
Generally, no. Modern molded rubber gaskets like those used on the Durango are designed to be installed dry. Always follow the specific instructions included with your gasket set. Applying sealant where it's not required can actually cause a leak.
Is this a good time to replace spark plugs?
Absolutely. On both the V6 and V8 engines, the intake manifold removal process gives you much easier access to the ignition coils and spark plugs. If your plugs are near the end of their service life, replacing them at the same time will save you significant time and money on future labor.
Why did my HEMI's intake bolts come loose?
It's a known quirk on some HEMI engines. The constant expansion and contraction from engine heat cycles can cause the intake manifold bolts to loosen slightly over time, creating a small vacuum leak. Some owners periodically check the torque on these bolts as a preventative measure.
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Technical Specifications
OEM Part Numbers: 68545089AA (5.7L/6.4L HEMI Gasket Kit) 5184331AC (3.6L V6 Lower Gasket - Set of 6) 5184562AC (3.6L V6 Upper Plenum Gasket) 68232614AA (3.6L V6 Lower Gasket - Updated Part #)
Gaskets are typically made of molded rubber, sometimes bonded to a plastic or metal carrier. The 3.6L V6 uses two separate sets for its upper and lower intake manifolds. The HEMI V8s use a set of individual port gaskets.
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The information in this article is provided for general reference and educational purposes only. Vehicle specifications, procedures, and part compatibility can vary by production date, trim level, and region. Always consult your vehicle's factory service manual and verify part numbers before purchasing or performing repairs. Safety-critical components such as airbags, seat belts, and braking systems should be installed by a qualified professional.
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- 🎬 Helpful Videos
- 🛍️ Shop This Part
- Is Your Durango's Intake Gasket Failing?
- Symptoms of a Vacuum Leak:
- Symptoms of a Coolant Leak:
- Known Issue: 2022-2023 Durango 5.7L Cracked Intake Manifold
- Choosing the Right Aftermarket Gasket Set
- Pro Tip for 3.6L Pentastar V6 Owners
- Cost to Replace Dodge Durango Intake Manifold Gaskets
- Frequently Asked Questions
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