300, Magnum, 2005

Oil Pan

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Removal & Installation



2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect negative battery cable located in trunk.
  4.  
  5. Remove engine oil indicator.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove lower splash shield retaining bolts and splash shield.
  10.  
  11. Drain engine oil and remove oil filter.
  12.  
  13. Remove the steering coupler bolt and separate coupler from rack.
  14.  
  15. Disconnect power steering pressure switch electrical connector.
  16.  
  17. Remove steering rack mounting bolts.
  18.  
  19. Remove power steering line support from frame.
  20.  
  21. Reposition rack out of the way.
  22.  
  23. Remove structural collar.
  24.  
  25. Remove alternator mounting bracket to oil pan lower bolt.
  26.  
  27. Remove air conditioning compressor bracket to oil pan lower bolt.
  28.  
  29. Remove lower timing chain cover to oil pan bolts.
    WARNING
    Assure removal of the four lower timing cover bolts, as damage to the timing cover and/or oil pan may occur.



    Click image to see an enlarged view

    Fig. Lower timing chain cover-to-oil pan bolts-2.7L engine

  30.  
  31. Remove oil pan attaching bolts. Remove oil pan and gasket.
  32.  

To install:

  1. Clean oil pan and sealing surfaces. Inspect timing chain cover gaskets. Replace as necessary.

    Click image to see an enlarged view

    Fig. Apply a 1/8 inch bead of Mopar® Engine RTV GEN II, or equivalent, to the front T-joints (1) and the rear T-joints (2)-2.7L engine

  2.  
  3. Apply a 1 / 8 inch bead of Mopar® Engine RTV GEN II, or equivalent, to the front T-joints (oil pan gasket to timing cover gasket interface) and the rear T-joints (oil pan gasket to crankshaft rear oil seal retainer gasket interface).
  4.  
  5. Install oil pan gasket to block.
    NOTE
    To prevent oil leaks at oil pan to timing chain cover, the following tightening sequence procedure must be performed.

  6.  
  7. Install oil pan and fasteners using the following tightening sequence:
    1. Install oil pan bolts and nuts finger tight only-just tight enough to compress the gasket-s rubber seal. Line up front of oil pan to be flush with front face of block.
    2.  
    3. Install lower timing chain cover bolts (1) and tighten to 105 inch lbs. (12 Nm).
    4.  
    5. Tighten oil pan bolts to 21 ft. lbs. (28 Nm).
    6.  
    7. Tighten oil pan nuts to 105 inch lbs. (12 Nm).
    8.  

  8.  
  9. Install lower bolt attaching the air conditioning compressor to oil pan. Tighten bolt to 21 ft. lbs. (28 Nm).
  10.  
  11. Install lower bolt attaching the alternator bracket to oil pan. Tighten bolt to 21 ft. lbs. (28 Nm).
  12.  
  13. Install oil filter and drain plug.
  14.  
  15. Install structural collar.
  16.  
  17. Position steering gear in place and install mounting bolts. Tighten bolts to 70 ft. lbs. (95 Nm).
  18.  
  19. Install the steering coupling lower pinch bolt at the gear using a new bolt. Tighten to 22 ft. lbs. (30 Nm).
  20.  
  21. Connect electrical connector to steering gear.
  22.  
  23. Install power steering line support and tighten.
  24.  
  25. Install lower splash shield and retaining bolts.
  26.  
  27. Lower vehicle.
  28.  
  29. Install engine oil level indicator.
  30.  
  31. Fill engine crankcase with proper oil to correct level.
  32.  
  33. Connect negative battery cable.
  34.  
  35. Start engine and check for leaks.
  36.  

3.5L Engines
2-Wheel Drive
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Lock the steering wheel in the center position.
  6.  
  7. Remove engine oil indicator.
  8.  
  9. Raise and support the vehicle.
  10.  
  11. Remove the splash shield.
  12.  
  13. Drain engine oil and remove the oil filter.
  14.  
  15. Drain cooling system.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Disconnect coolant hoses from oil cooler.
  20.  
  21. Remove oil filter.
  22.  
  23. Remove oil cooler attaching fastener from center of oil cooler.
  24.  
  25. Remove oil cooler.
  26.  
  27. Separate the steering column coupler from the steering gear.
  28.  
  29. Remove steering gear to cradle mounting bolts and suspend steering gear aside
  30.  
  31. Remove the flex plate access cover.

    Click image to see an enlarged view

    Fig. Rear oil pan (2) to transmission (3) bolts (1)-3.5L engine

  32.  
  33. Remove the rear oil pan to transmission bolts.

    Click image to see an enlarged view

    Fig. Rear oil pan bolts-3.5L engine

  34.  
  35. Remove the two rear oil pan bolts.
  36.  
  37. Remove the remaining oil pan bolts.
  38.  
  39. Loosen the engine mount bolts at the cradle.
  40.  
  41. Raise and support the engine using a suitable floor jack with a block of wood at the transmission housing.
  42.  
  43. Remove the oil pan.
    NOTE
    A small amount of oil will remain in the oil pan. Use care when removing the oil pan from the engine.

  44.  
  45. Clean all mating surfaces.
  46.  

To install:

Click image to see an enlarged view

Fig. Oil pan sealer application-3.5L engine

  1. Clean oil pan and all gasket surfaces.
  2.  
  3. Apply a 1 / 8 inch bead of Mopar® Engine RTV GEN II, or equivalent, at the parting line of the oil pump housing and the rear seal retainer.

    Click image to see an enlarged view

    Fig. Oil pan and gasket installation-3.5L engine

  4.  
  5. Install oil pan gasket to the engine block.
  6.  
  7. Install the oil pan while aligning the oil level indicator tube and attach fasteners finger tight.
    NOTE
    Assure that the rear face of the oil pan is flush to the transmission bell housing when installing the oil pan.

  8.  
  9. Pre-torque the horizontal rear oil pan to transmission bolts to 12 inch lbs. (1.4 Nm).

    Click image to see an enlarged view

    Fig. First tighten the M8 (1) oil pan alignment bolt to 21 ft. lbs. (28 Nm), then tighten bolt (2) to 21 ft. lbs. (28 Nm) (250 inch lbs.)-3.5L engine

  10.  
  11. First tighten the M8 oil pan alignment bolt to 21 ft. lbs. (28 Nm), then tighten bolt to 21 ft. lbs. (28 Nm).
  12.  
  13. Tighten the remaining M8 bolts and M8 nuts to 21 ft. lbs. (28 Nm), and the M6 bolts to 105 inch lbs. (12 Nm).
  14.  
  15. Tighten the four M10 oil pan to transmission bolts to 40 ft. lbs. (55 Nm).
  16.  
  17. Lower the engine and remove the lifting fixture. Tighten the engine mount to cradle fasteners to 55 ft. lbs. (75 Nm).
  18.  
  19. Install the flex plate inspection cover and tighten the fastener to 97 inch lbs. (11 Nm)
  20.  
  21. Position oil cooler to fitting on oil pan.
    NOTE
    Remove all oil and debris from the seal retainer surface. The cut out section of the oil cooler seal retainer flange (top) must be aligned with the tab on the oil pan. The oil cooler must be prevented from turning during the tightening sequence.

  22.  
  23. Install oil cooler attaching fastener and tighten to 55 ft. lbs. (75 Nm).
  24.  
  25. Install oil filter and tighten to 106 inch lbs. (12 Nm).
  26.  
  27. Connect coolant hoses to oil cooler.
  28.  
  29. Fill cooling system.
  30.  
  31. Install the engine oil filter.
  32.  
  33. Install the steering gear to cradle bolts and tighten the fasteners to 70 ft. lbs. (95 Nm).
  34.  
  35. Connect the steering gear coupler and tighten the fastener to 22 ft. lbs. (30 Nm)
  36.  
  37. Attach the splash shield.
  38.  
  39. Lower the vehicle.
  40.  
  41. Install the engine oil indicator.
  42.  
  43. Fill engine crankcase with proper oil to correct level.
  44.  
  45. Connect negative battery cable.
  46.  

All Wheel Drive
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the oil level indicator tube fastener at the right exhaust manifold.
  8.  
  9. Raise and support the vehicle.
  10.  
  11. Drain engine oil and remove the oil filter.
  12.  
  13. Remove the left axle shaft.
  14.  
  15. Disconnect the power steering hoses from the power steering rack.
  16.  
  17. Remove the left front axle intermediate shaft support bracket and housing.
  18.  
  19. Remove the front drive shaft heat shield.
  20.  
  21. Paint mark and remove the front driveshaft.
  22.  
  23. Remove the right catalytic converter.
  24.  
  25. Separate the power steering hose from cradle hold down and position the hose aside.
  26.  
  27. Remove the lower engine mount to cradle fasteners.
  28.  
  29. Remove the front sway bar.
  30.  
  31. Raise and support the engine with a jackstand.
  32.  
  33. Remove the front axle housing support bracket.
  34.  
  35. Remove the front axle housing fasteners, rotate the housing position and remove the axle housing.
  36.  
  37. Lower the engine and remove the jackstand.
  38.  
  39. Disconnect coolant hoses from oil cooler.
  40.  
  41. Remove oil filter.
  42.  
  43. Remove oil cooler attaching fastener from center of oil cooler.
  44.  
  45. Remove oil cooler.
  46.  
  47. Separate the oil level indicator tube from the oil pan.
  48.  
  49. Remove the torque converter access cover.
  50.  
  51. Remove the oil pan.
  52.  

To install:

  1. Clean oil pan and all mating surfaces.
  2.  
  3. Replace the oil level indicator tube seal.
  4.  
  5. Apply a 1 / 8 inch bead of Mopar® Engine RTV GEN II, or equivalent, at the parting line of the oil pump housing and the rear seal retainer.
  6.  
  7. Install the oil pan gasket to the engine block.
  8.  
  9. Install the oil pan while aligning the oil level indicator tube and attach the fasteners finger tight.
    NOTE
    Assure that the rear face of the oil pan is flush to the transmission bell housing when installing the oil pan.

  10.  
  11. Pre-torque the horizontal rear oil pan to transmission bolts to 12 inch lbs. (1.4 Nm)
  12.  
  13. First tighten the M8 oil pan alignment bolt to 21 ft. lbs. (28 Nm), then tighten bolt to 21 ft. lbs. (28 Nm).
  14.  
  15. Tighten the remaining M8 bolts and M8 nuts to 21 ft. lbs. (28 Nm), and the M6 bolts to 105 inch lbs. (12 Nm).
  16.  
  17. Tighten the four M10 oil pan to transmission bolts to 40 ft. lbs. (55 Nm).
  18.  
  19. Install the torque converter access cover and tighten the fastener to 97 inch lbs. (11 Nm).
  20.  
  21. Position oil cooler to fitting on oil pan.
    NOTE
    Remove all oil and debris from the seal retainer surface. The cut out section of the oil cooler seal retainer flange (top) must be aligned with the tab on the oil pan. The oil cooler must be prevented from turning during the tightening sequence.

  22.  
  23. Install oil cooler attaching fastener and tighten to 55 ft. lbs. (75 Nm).
  24.  
  25. Install oil filter and tighten to 106 inch lbs. (12 Nm).
  26.  
  27. Connect coolant hoses to oil cooler.
  28.  
  29. Support the engine with a jackstand.
  30.  
  31. Install the front drive axle housing. Tighten mounting bolts to oil pan to 48 ft. lbs. (65 Nm).
  32.  
  33. Remove the jackstand.
  34.  
  35. Install the front drive axle housing support.
  36.  
  37. Install the front suspension sway bar to cradle.
  38.  
  39. Install the engine mount to front cradle fasteners. Tighten the fasteners to 55 ft. lbs. (75 Nm).
  40.  
  41. Position and install the power steering hose to cradle hold downs.
  42.  
  43. Install the right catalytic converter.
  44.  
  45. Align the paint marks and install the front drive shaft.
  46.  
  47. Install the front drive shaft heat shield.
  48.  
  49. Install the left front drive axle intermediate shaft housing and support bracket. Tighten fasteners to 19 ft. lbs. (25 Nm).
  50.  
  51. Connect the power steering hoses to the steering rack.
  52.  
  53. Install the left front drive axle.
  54.  
  55. Install the right front drive axle.
  56.  
  57. Lower the vehicle.
  58.  
  59. Install the oil level indicator tube fastener to the right exhaust manifold.
  60.  
  61. Fill engine crankcase with the proper oil to the correct level.
  62.  
  63. Fill the cooling system.
  64.  
  65. Fill the power steering.
  66.  
  67. Connect the negative battery cable.
  68.  

5.7L Engines
2-Wheel Drive
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the intake manifold.
  6.  
  7. Install engine lift fixture special tool 8984 and adapter 8984-UPD. See the Engine Removal & Installation procedure.
    WARNING
    Never use air tools when installing fasteners to engine.

  8.  
  9. Raise vehicle.
  10.  
  11. Remove the belly pan.
  12.  
  13. Drain engine oil and remove the oil filter.
  14.  
  15. Unbolt and lower the steering rack from the mounts. Do not remove power steering hoses, tie rod ends or disconnect steering column.
  16.  
  17. Remove both left and right side engine hydromount to frame nuts, and studs.
  18.  
  19. Remove the engine oil dipstick and tube from the oil pan.
  20.  
  21. Lower the vehicle.
  22.  
  23. Install engine support fixture special tool 8534. Do not use the third leg. See the Engine Removal & Installation procedure.
  24.  
  25. Raise engine using special tool 8534 and 8984 to provide clearance to remove oil pan.
    NOTE
    Do not pry on oil pan or oil pan gasket. Gasket is integral to engine windage tray and does not come out with oil pan.


    NOTE
    The horizontal M10 fasteners are 5 mm longer in length, and must be reinstalled in original locations.

  26.  
  27. Remove the M10 fasteners (vertical and horizontal) from the rear of the oil pan to the transmission and engine.
  28.  
  29. Remove the oil pan mounting bolts and oil pan.
    NOTE
    When the oil pan is removed, a new oil pan gasket/windage tray assembly must be installed. The old gasket cannot be reused.

  30.  
  31. Discard the integral windage tray and gasket and replace.
  32.  

To install:

Click image to see an enlarged view

Fig. RTV sealer application-5.7L engine

  1. Clean the oil pan gasket mating surface of the block and oil pan.
    NOTE
    Mopar® Engine RTV must be applied to the 4 T-joints, (area where front cover, rear retainer, block, and oil pan gasket meet). The bead of RTV should cover the bottom of the gasket. This area is approximately 4.5 mm x 25 mm in each of the 4 T-joint locations.

  2.  
  3. Apply Mopar® Engine RTV at the 4 T- joints.
    NOTE
    When the oil pan is removed, a new oil pan gasket/windage tray assembly must be installed. The old gasket cannot be reused.

  4.  
  5. Install a new oil pan gasket/windage tray assembly.
  6.  
  7. If removed, reinstall the oil pump pickup tube with new O-ring. Tighten tube to pump fasteners to 21 ft. lbs. (28 Nm).
    NOTE
    The horizontal M10 fasteners are 5 mm longer in length, and must be reinstalled in original locations.



    Click image to see an enlarged view

    Fig. Oil pan bolt torque sequence-5.7L engine

  8.  
  9. Align the rear of the oil pan with the rear face of the engine block, and install the M10 and M6 oil pan fasteners finger tight. Using the accompanying torque sequence, torque the M6 mounting bolts to 44 inch lbs. (5 Nm).
  10.  
  11. Using the accompanying torque sequence, torque the M10 oil pan fasteners to 39 ft. lbs. (54 Nm).
  12.  
  13. Using the accompanying torque sequence, torque the M6 oil pan fasteners to 106 inch lbs. (12 Nm).
  14.  
  15. Lower the engine into mounts using special tool 8534.
  16.  
  17. Install both the left and right side engine mount studs and nuts. Torque the studs and nuts to 70 ft. lbs. (95 Nm).
  18.  
  19. Install the engine oil dipstick and tube.
  20.  
  21. Install the steering rack.
  22.  
  23. Remove special tool 8534.
  24.  
  25. Remove special tool 8984.
  26.  
  27. Install the intake manifold.
  28.  
  29. Fill engine oil.
  30.  
  31. Install oil filter, if removed.
  32.  
  33. Reconnect the negative battery cable.
  34.  
  35. Start engine and check for leaks.
  36.  
  37. Install the belly pan.
  38.  

All Wheel Drive
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine cover.
  6.  
  7. Remove the intake manifold.
  8.  
  9. Install engine lift fixture special tool 8984 and adapter 8984-UPD. See the Engine Removal & Installation procedure.
    NOTE
    Never use air tools when installing fasteners to engine.

  10.  
  11. Raise vehicle.
  12.  
  13. Remove the belly pan.
  14.  
  15. Remove both left and right side engine mount to frame fasteners.
  16.  
  17. Drain engine oil and remove the oil filter.
  18.  
  19. Unbolt and lower the steering rack from the mounts. Do not remove power steering hoses, tie rod ends or disconnect steering column.
  20.  
  21. Remove the engine oil dipstick and tube from the oil pan.
  22.  
  23. Remove the left and right side exhaust at the manifolds.
  24.  
  25. Mark the front driveshaft to the flange at both ends to ensure correct installation.
  26.  
  27. Remove front driveshaft fasteners from the differential and transfer case. Remove the driveshaft from the vehicle.
  28.  
  29. Remove the left and right front drive axles.
  30.  
  31. Remove the differential support bracket from the differential to the engine block.
  32.  
  33. Unbolt the differential from the oil pan.
  34.  
  35. Rotate the differential so the drive flange is facing forward and the oil pan side is facing up. Remove the differential out through the opening at the rear of the cradle.
  36.  
  37. Remove the intermediate shaft from the oil pan.
  38.  
  39. Lower the vehicle.
  40.  
  41. Install engine support fixture special tool 8534. Do not attempt to fasten fixture to vehicle body, or attach the third support leg to the radiator support. See the Engine Removal & Installation procedure.
  42.  
  43. Raise engine using special tool 8534 and 8984 to provide clearance to remove oil pan.
  44.  
  45. Raise vehicle.
    NOTE
    Do not pry on oil pan or oil pan gasket. Gasket is integral to engine windage tray and does not come out with oil pan.


    NOTE
    The horizontal M10 fasteners are 5 mm longer in length, and must be reinstalled in original locations.

  46.  
  47. Remove the M10 fasteners (vertical and horizontal) from the rear of the oil pan to the transmission and engine.
  48.  
  49. Remove the oil pan mounting bolts and oil pan.
    NOTE
    When the oil pan is removed, a new oil pan gasket/windage tray assembly must be installed. The old gasket cannot be reused.

  50.  
  51. Discard the integral windage tray and gasket and replace.
  52.  

To install:

  1. Clean the oil pan gasket mating surface of the block and oil pan.
    NOTE
    Mopar® Engine RTV must be applied to the 4 T-joints, (area where front cover, rear retainer, block, and oil pan gasket meet). The bead of RTV should cover the bottom of the gasket. This area is approximately 4.5 mm x 25 mm in each of the 4 T-joint locations.

  2.  
  3. Apply Mopar® Engine RTV at the 4 T- joints.
    NOTE
    When the oil pan is removed, a new oil pan gasket/windage tray assembly must be installed. The old gasket cannot be reused.

  4.  
  5. Install a new oil pan gasket/windage tray assembly.
  6.  
  7. If removed, reinstall the oil pump pickup tube with new O-ring. Tighten tube to pump fasteners to 21 ft. lbs. (28 Nm).
    NOTE
    The horizontal M10 fasteners are 5 mm longer in length, and must be reinstalled in original locations.

  8.  
  9. Align the rear of the oil pan with the rear face of the engine block, and install the M10 and M6 oil pan fasteners finger tight. Using the following torque sequence, torque the M6 mounting bolts to 44 inch lbs. (5 Nm).
  10.  
  11. Using the following torque sequence, torque the M10 oil pan fasteners to 39 ft. lbs. (54 Nm).
  12.  
  13. Using the following torque sequence, torque the M6 oil pan fasteners to 106 inch lbs. (12 Nm).
  14.  
  15. Install the intermediate shaft to the oil pan. Torque fasteners to 21 ft. lbs. (28 Nm).
  16.  
  17. Install the front differential through the opening at the rear of the cradle, and attach to the oil pan.
  18.  
  19. Fasten the differential to the oil pan. Torque to 48 ft. lbs. (65 Nm).
  20.  
  21. Install the differential support bracket to the differential and the engine block.
  22.  
  23. Install the left and right front drive axles.
  24.  
  25. Install front driveshaft into the differential and transfer case.
  26.  
  27. Install the engine oil dipstick and tube.
  28.  
  29. Install the steering gear.
  30.  
  31. Lower the engine into mounts using special tool 8534.
  32.  
  33. Install both the left and right side engine mount studs and nuts. Torque to 70 ft. lbs. (95 Nm).
  34.  
  35. Remove special tool 8534.
  36.  
  37. Remove special tool 8984.
  38.  
  39. Install the intake manifold.
  40.  
  41. Install the left and right side exhaust at the manifolds.
  42.  
  43. Fill engine oil.
  44.  
  45. Install oil filter, if removed.
  46.  
  47. Reconnect the negative battery cable.
  48.  
  49. Start engine and check for leaks.
  50.  
  51. Install the engine cover.
  52.  

 
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