Chrysler Full-Size Trucks 1989-1996 Repair Guide

Oil Pan

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REMOVAL & INSTALLATION



2.5L Engine

See Figure 1

  1. Disconnect the negative battery cable. Remove the oil dipstick.
  2.  
  3. Disconnect the air pump relief valve upper hose. Raise the vehicle and support safely.
  4.  
  5. Remove the clutch housing to engine strut and clutch inspection cover.
  6.  
  7. Remove the lower radiator hose support bracket.
  8.  
  9. Slightly loosen the right motor mount through-bolt just enough to relieve the tension.
  10.  
  11. Using the proper equipment, support the weight of the engine. Loosen the left motor mount through-bolt enough to clear the bracket.
  12.  



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Fig. Fig. 1: Front and rear oil seals-2.5L engine

  1. Raise the left side of the engine about 2 in. (51mm).
  2.  
  3. Remove the oil pan retaining screws and remove the oil pan and gasket.
  4.  

To install:
  1. Thoroughly clean and dry all sealing surfaces, bolts and bolt holes.
  2.  
  3. Apply silicone sealer to the four end seal to block corners and install the end seals making sure the corners are not twisted.
  4.  
  5. Apply silicone to the four pan to block corners. Install a new pan gasket or apply a silicone sealer to the sealing surface of the pan and install to the engine making sure not to dislodge the end seals.
  6.  
  7. Install the pan retaining screws and tighten to 17 ft. lbs. (23 Nm).
  8.  
  9. Lower the engine. Tighten the motor mount through-bolts to 50 ft. lbs. (68 Nm).
  10.  
  11. Install the clutch inspection cover and housing to engine strut. Install the lower radiator hose support bracket. Lower the vehicle.
  12.  
  13. Install the dipstick and air pump hose. Fill the engine with the proper amount of oil.
  14.  
  15. Connect the negative battery cable and check for leaks.
  16.  

3.9L Engine

2-WHEEL DRIVE

See Figure 2

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Fig. Fig. 2: Always install a new oil pan gasket on a clean surface-V6 engine shown

  1. Disconnect the negative battery cable. Remove the oil dipstick. Disengage the distributor cap and remove it away from the firewall.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the exhaust crossover.
  8.  
  9. Loosen the motor mount bolts. Using the proper equipment, raise the engine. When the engine is high enough, install replacement bolts (similar in size to the motor mount bolts), in the engine mount attaching points on the frame brackets.
  10.  
  11. Lower the engine so the bottom of the motor mounts rest on the two replacement bolts. Remove the torque converter inspection cover, if equipped.
  12.  
  13. Remove the oil pan retaining screws and remove the oil pan and gaskets.
  14.  

To install:
  1. Thoroughly clean and dry all sealing surfaces, bolts and bolt holes.
  2.  
  3. Place a drop of silicone sealer to the timing chain cover to block mating seam.
  4.  
  5. Install the new gaskets to the engine and add a drop of silicone sealer to the corners where the rubber and cork meet. Instal the rubber seals to the pan.
  6.  
  7. Install the pan to the engine and tighten the retaining screws to 17 ft. lbs. (23 Nm). Install the torque converter inspection cover, if equipped.
  8.  
  9. Reinstall the engine to the mount and install the exhaust crossover. Lower the vehicle.
  10.  
  11. Install the distributor cap.
  12.  
  13. Install the dipstick. Fill the engine with the proper amount of oil.
  14.  
  15. Connect the negative battery cable and check for leaks.
  16.  

4-WHEEL DRIVE

See Figures 3, 4, 5 and 6

  1. Disconnect the negative battery cable. Remove the oil dipstick.
  2.  
  3. Raise the vehicle and support safely.
  4.  



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Fig. Fig. 3: Remove the crossmember to keep it from interfering with the oil pan removal

  1. Using the proper equipment, support the weight of the engine. Remove the front driving axle.
  2.  



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Fig. Fig. 4: Unbolt the pan using the correct socket and an extension of suitable length

  1. Remove the exhaust crossover and the lower transmission cover.
  2.  



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Fig. Fig. 5: Maneuver the oil pan out and down from the engine

  1. Remove the oil pan retaining screws and remove the oil pan and gaskets.
  2.  

To install:


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Fig. Fig. 6: Scrape all remaining gasket and old sealer away from the mating surfaces

  1. Thoroughly clean and dry all sealing surfaces, bolts and bolt holes.
  2.  
  3. Place a drop of silicone sealer to the timing chain cover to block mating seam.
  4.  
  5. Install the new gaskets to the engine and add a drop of silicone sealer to the corners where the rubber and cork meet. Install the rubber seals to the pan.
  6.  
  7. Install the pan to the engine and tighten the retaining screws to 17 ft. lbs. (23 Nm). Install the lower transmission cover, if equipped.
  8.  
  9. Install the exhaust crossover.
  10.  
  11. Install the front driving axle. Lower the vehicle.
  12.  
  13. Install the dipstick. Fill the engine with the proper amount of oil.
  14.  
  15. Connect the negative battery cable and check for leaks.
  16.  

5.2L and 5.9L Engine

See Figure 7

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the oil dipstick.
  4.  
  5. Raise and support the front end on jackstands.
  6.  
  7. Drain the oil.
  8.  



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Fig. Fig. 7: Always install a new oil pan gasket on a clean surface-V8 engine shown

  1. Remove the exhaust cross-over pipe.
  2.  
  3. Remove the left engine-to-transmission strut.
  4.  
  5. Remove the bolts and lower the oil pan.
  6.  
  7. Thoroughly clean the gasket mating surfaces.
  8.  
  9. When installing the pan, always use new gaskets coated with sealer. Apply a drop of RTV silicone sealer where the cork and rubber gaskets meet. On the 5.9L engine, make sure the gasket notches are positioned as shown. Tighten the oil pan bolts to 15 ft. lbs. (20 Nm). Tighten the cross-over pipe to 24 ft. lbs. (32 Nm).
  10.  

8.0L Engine

See Figures 8 and 9

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the oil dipstick.
  4.  
  5. Raise and support the front end on jackstands.
  6.  
  7. Drain the oil.
  8.  
  9. Remove the left engine-to-transmission strut.
  10.  
  11. Remove the bolts and lower the oil pan. Remove the one piece gasket. The engine may have to be raised slightly on 2WD vehicles.
  12.  
  13. Remove the oil pickup tube assembly.
  14.  

To install:
  1. Thoroughly clean the gasket mating surfaces. If present, trim excess gasket sealant from the inside of the engine.
  2.  



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Fig. Fig. 8: Fabricate four alignment dowels by cutting the bolt heads off and slotting the tops-V10 engine



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Fig. Fig. 9: Oil pan mounting bolt and stud location-V10 engine

  1. Clean the oil pan with solvent and dry thoroughly with a lint-free cloth.
  2.  
  3. Clean the oil screen and pipe. Inspect the condition of the screen.
  4.  
  5. Fabricate four alignment dowels from 5 / 16 x 1 1 / 2 in. bolts. Cut the heads off the bolts and cut a slot in the top to allow installation and removal with a screwdriver.
  6.  
  7. Install the dowels into the four corners with a screwdriver.
  8.  
  9. Apply a small quantity of Mopar® Silicon Rubber Adhesive Sealant, or equivalent at the split lines. These are between the cylinder block, timing chain cover and rear crankshaft seal.
  10.  

After the sealant is applied, you have three minutes to install the gasket and oil pan.

  1. Slide the one-piece gasket over the alignment dowels and position it on the block.
  2.  
  3. Position the oil pan over the gasket. The engine may have to be raised slightly on 2WD vehicles.
  4.  
  5. Install the bolts. Tighten the 1 / 2 in. bolts to 96 inch lbs. (11 Nm). Tighten the stud bolts to 144 inch lbs. (16 Nm). Tighten the 5 / 16 in. bolts to 144 inch lbs. (16 Nm).
  6.  
  7. Remove the dowels and, in their place, install the four remaining 5 / 16 in. bolts. Tighten these bolts to 144 inch lbs. (16 Nm).
  8.  
  9. Install the drain plug. Tighten it to 25 ft. lbs. (34 Nm).
  10.  
  11. Install the engine-to-transmission strut.
  12.  
  13. Lower the vehicle. Connect the negative battery cable. Fill the crankcase with oil.
  14.  

 
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