Chrysler Full-Size Trucks 1967-1988 Repair Guide

Front Cover and Seal

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REMOVAL & INSTALLATION



If replacing only a cover seal, the cover does not have to be removed. With the balancer removed, the seal can be replaced.

Inline 6 Cylinder Gasoline Engines

See Figure 1

  1. Drain the cooling system and disconnect the battery cable.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the radiator and fan.
  2.  
  3. With a puller, remove the vibration damper.
  4.  
  5. Loosen the oil pan bolts to allow clearance, then remove the timing case cover and gasket.
  6.  
  7. Clean all gasket surfaces thoroughly.
  8.  
  9. Install a new seal in the case.
  10.  
  11. Install the timing case cover with a new gasket and torque the bolts to 17 ft. lbs. (23 Nm). Re-tighten the engine oil pan to 17 ft. lbs. (23 Nm). Always use a centering tool to ensure that the seal will not be damaged and that it is properly aligned.
  12.  
  13. On the 6-198 and 6-225, press the vibration damper back on. On the 6-251, install the damper and torque the bolt to 135 ft. lbs. (182 Nm)
  14.  



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Fig. Fig. 1: The damper nut may be run on with an open-end wrench, but a torque wrench is necessary for proper tightening

  1. Replace the radiator and hoses.
  2.  
  3. Connect the battery cable.
  4.  
  5. Refill the cooling system.
  6.  

V6 and V8 Gasoline Engines
EXCEPT 8-413

See Figures 2 through 9

  1. Disconnect the battery and drain the cooling system. Remove the radiator.
  2.  
  3. Remove the water pump.
  4.  
  5. Remove the power steering pump.
  6.  
  7. Remove the crankshaft pulley by using a large socket and another wrench to hold the small bolts.
  8.  



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Fig. Fig. 2: Remove the crankshaft pulley for access to the damper

  1. Mark the vibration damper with white paint at the Top Dead Center (TDC) timing mark.
  2.  



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Fig. Fig. 3: To ease assembly, always align the TDC mark on the pulley to the 0° timing mark on the front cover

  1. Loosen the crankshaft bolt with a wrench and put aside.
  2.  



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Fig. Fig. 4: Loosen and remove the crankshaft bolt

  1. Remove the vibration damper with a puller. On 318 and 360 engines, remove the fuel lines and fuel pump, then loosen the oil pan bolts and remove the front bolt on each side.
  2.  



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Fig. Fig. 5: Always use a threaded puller to remove the damper-jawed pullers would damage dampers with bonded hubs

When the upper bolt is removed, fluid may come out.

  1. Remove the timing gear cover and the crankshaft oil slinger.
  2.  
  3. Remove the seal with a suitable prytool, place the tool behind the lip of the seal and pry upwards. Do this carefully making sure not to damage the crankshaft seal surface of the cover.
  4.  

A seal remover and installer tool is required to prevent seal damage.



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Fig. Fig. 6: Carefully pry the oil seal out

  1. Clean all gasket surfaces thoroughly.
  2.  

To install:
  1. Install a new seal in the cover. Use a socket placed evenly over the seal and apply blows with a hammer.
  2.  
  3. Insert the seal into the opening with the springs towards the inside of the engine. Make sure to lube the seal first before installing.
  4.  



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Fig. Fig. 7: Use a socket and hammer to install the new oil seal

  1. Install the timing case cover with a new gasket. A 1 / 8 in. (25.5mm) bead of RTV sealer is recommended on the oil pan gasket. Torque the cover bolts to 30 ft. lbs. (41 Nm). Retighten the engine oil pan to 17 ft. lbs. (23 Nm). Always use a centering tool to ensure that the seal will not be damaged and that it is properly aligned.
  2.  



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Fig. Fig. 8: Position the new gasket and coat with a bead of sealer



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Fig. Fig. 9: Be sure to use a thin bead of RTV sealant at the oil pan gasket mating surface

  1. Lubricate the seal lip with lithium white grease and slide the damper back into position. Using tool C-3688, press the damper onto the shaft. When reinstalling the bolt, use a sealant on the bolt surface. Torque the bolt to 135 ft. lbs. (182 Nm).
  2.  
  3. On the 318 and 360 engines install the fuel pump and lines.
  4.  
  5. Install the water pump, using new gaskets and tighten to 30 ft. lbs. (41 Nm).
  6.  
  7. Install the power steering pump.
  8.  
  9. Replace the radiator and hoses.
  10.  
  11. Tighten all drive belts.
  12.  
  13. Connect the battery cable.
  14.  
  15. Fill the cooling system.
  16.  

8-413 ENGINE
  1. Remove the cover as outlined in the previous procedure.
  2.  
  3. Position remover screw of Tool C-3506 through case cover, inside of case cover up.
  4.  
  5. Position remover blocks directly opposite each other, and force angular lip between neoprene and flange of seal retainer.
  6.  
  7. Place washer and nut on remover screw.
  8.  
  9. Tighten nut as tightly as possible by hand, forcing blocks into gap to a point of distorting the seal retainer lip. Remove blocks and screw are then in proper position.
  10.  
  11. Place sleeve over retainer and place removing and installing plate into sleeve. Place flat washer and nut on remover screw. Hold center screw and tighten lock nut to remove seal.
  12.  
  13. Insert remover screw through removing and installing plate so that thin shoulder will be facing up.
  14.  

To install:
  1. Insert remover screw with plate through seal opening (inside of gear case cover facing up.) Place seal in cover opening, with neoprene down.
  2.  
  3. Place seal installing plate into new seal, with protective recess toward lip off seal retainer.
  4.  
  5. Install flat washer and nut on remover screw, hold screw and tighten the nut. The seal is properly installed when neoprene is tight against face of cover.
  6.  
  7. Try to insert a 0.0015 in. (0.038mm) feeler gauge between neoprene and cover. If seal is installed properly, feeler gauge cannot be inserted. It is normal to find particles of neoprene collected between seal retainer and crankshaft oil slinger after seal has been in operation.
  8.  
  9. Be sure mating surfaces of gear case cover and cylinder block are clean and free from burrs.
  10.  
  11. Lubricate oil seal with Lubriplate® using a new gasket, slide gear cover over locating dowels and tighten upper four 5 / 16 (25.7mm) bolts to 15 ft. lbs. (20 Nm). Install front engine mount using lower four holes. Be sure to use special hardened bolts with beveled washers. Tighten to 40 ft. lbs. ( 54 Nm).
  12.  

6-243 Diesel Engines
  1. Disconnect the battery ground cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect and remove the upper and lower hoses.
  6.  
  7. Unhook the overflow tank.
  8.  
  9. Remove the automatic transmission oil cooler lines and bracket.
  10.  
  11. Loosen the radiator mount bolts.
  12.  
  13. Remove the fan.
  14.  
  15. Take out the rubber shield from between the radiator and grille.
  16.  
  17. Remove the radiator and fan shroud.
  18.  
  19. Remove all drive belts.
  20.  
  21. Loosen and remove the crankshaft pulley nut.
  22.  
  23. Turn the crankshaft until the keyway is at the 12 o'clock position.
  24.  
  25. Mark the vibration damper with white paint TDC, 0° timing mark for correct installation.
  26.  
  27. Remove the crankshaft pulley and damper assembly with tool MH-061101.
  28.  
  29. Remove the timing gear case and gasket.
  30.  
  31. Remove the front oil seal from the case.
  32.  

A seal remover and installer tool is required to prevent seal damage.

  1. Coat a new timing case gasket with sealer and position it over the dowels on the block.
  2.  

To install:
  1. Install the timing gear case Torque the bolts to 84 inch lb. (9 Nm).
  2.  
  3. Install the crankshaft pulley and damper assembly. Be careful to avoid damage to the seal.
  4.  
  5. Install the crankshaft pulley cone and nut. Torque the nut to 290 ft. lbs. (392 Nm).
  6.  
  7. Install all drive belts.
  8.  
  9. Install the radiator and fan shroud. Tighten the lower radiator mounting nuts finger-tight.
  10.  
  11. Install the rubber shield between the radiator and grille.
  12.  
  13. Install the fan.
  14.  
  15. Align the radiator and tighten the radiator mount bolts.
  16.  
  17. Install the automatic transmission oil cooler lines and bracket.
  18.  
  19. Connect the overflow tank.
  20.  
  21. Install and tighten the upper and lower radiator hoses.
  22.  
  23. Connect the battery cable.
  24.  
  25. Fill the cooling system.
  26.  
  27. Check for leaks
  28.  

 
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