Temp ranges on the 5 D2's I've owned have all varied. I had one 02 that ran 205-215F and never gave me any trouble. Then I had two 03's that ran 195-205F, and 04 that ran 195-210F, and my current 02 Kalahari with 224K on it (the highest mileage D2 I've ever owned) runs 175-193F. I use a ScanGauge II to monitor my Alternator voltage, engine temp, Air Intake temp, and RPM's.

Switching to a 180F thermostat does wonders, a new Hayden Fan Clutch will also help, but since you have an 03 you will have to replace the fan with one from a 99-02 as the 03/04 units are one piece which won't allow you to change just the fan clutch out.

I'd also suggest changing to normal green antifreeze vs the red/pink stuff.

 

I had the same idea when I last had the upper intake chamber pulled off. I wasn't in the mood to crack the cooling system open, or I would have pondered on the retrofit of a thermostat onto the block.

 

Is the Kalahari the only truck with the inline Tstat setup?

 

Bought a used intake off ebay. Trying to find a thermostat to fit.

 

Normal LR 180F Thermostat in my Kalahari.

 

That's whats up. Would you do me a favor and keep me updated on that?

 

No problem. I lost the sheet with the measurements, but I'll re-measure the space tonight and pass it along. That way, if you see something that works, you can let me know.

 

DGI O7,

I had the same idea using stock lower intake and a Dorman thermostat housing #901109.

unfortunately I cant cut and paste,

but if you pull up a picture, it looks like the easy modification to make it fit, and it has a by pass for the heater core

 

Hey drow, that part number doesn't come up. Closest thing Google shows is #902-204 which unfortunately, no way in sweet baby Jesus' name, will fit. Just entirely to big. In addition, if you look at the water neck coming off the lower intake, its just way too tight in there (thats what she said), which is why I want to put the thermo right in the manifold.

Glad to know I'm not the only thinking along this line. We should start our own thread. Sorry to threadjack OP.

 

902-109 (a little dyslexic that and a photographic memory are a great pair)

I figure you may have to open hole the manifold slightly,
after that it should be a matter of drilling and tapping in the right postion