1996 Roadtrek Popular 190 Water Heater Replacement

[VTPete]

I've looked up and down the forums and couldn't find anyone reference to replacing the water heater on my 1996 Dodge Roadtrek Popular 190. It still works - but is certainly on its last legs with several issues such as the thermostat allowing it to get way too hot, the water getting brown after sitting for only a day or two, etc. Bits and pieces of rust come out when I flush it.

Replacements are easy to find. Pulling out the old one and installing the new seems as simple as that - but I'm sure there are gotchas where having someone else's prior experience would be helpful!

 

[RT-NY]

I have also searched online and asked on this forum about changing out the water heater in Dodge Roadtreks of this era, but I haven't seen anything from anyone who had done it. I expect it would be, as you say, simple. The main issue I would foresee is completely removing and then replacing the black seal that fits between the outside water heater door frame and the oddly shaped outside wall of the van.

 

[VTPete]

I have also searched online and asked on this forum about changing out the water heater in Dodge Roadtreks of this era, but I haven't seen anything from anyone who had done it. I expect it would be, as you say, simple. The main issue I would foresee is completely removing and then replacing the black seal that fits between the outside water heater door frame and the oddly shaped outside wall of the van.

Indeed! I almost wrote, "I bet the tough part will be the black butyl goop - removing it and adding a new seal without making it look like a nightmare job." I will likely leave this until next year - or this fall.

 

[RT-NY]

I hope to do this job myself eventually -- the tank on my 1999 RT 170 is leaking so I don't use it any more. My tentative planning was to remove the old seal by gently scraping it off, using a new door frame (which I already have because I lost the door on the road some years ago, so I bought a new one which also comes with the frame), and trying to make a new seal using black butyl tape of the appropriate width, trying to layer it to get the varied thicknesses right.