Chrysler Full-Size Trucks 1989-1996 Repair Guide

Rear Main Seal

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The 3.9L and 5.2L engine rear main oil seal is a 2-piece, fitted rope type seal. The 5.9L engine rear main seal is a split rubber type in all cases. The upper half can be installed with the crankshaft in place. The 2 halves should always be replaced as a set.

REMOVAL & INSTALLATION



2.5L Engine

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the transmission or transaxle. Remove the flywheel of flexplate.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Use a prytool to extract the rear crankshaft oil seal-2.5L engine

  1. If there is any leakage coming from the rear seal retainer, drain the engine oil and remove the oil pan, if necessary. Remove the rear main oil seal retainer.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Use the special tool, or equivalent, to press in the rear crankshaft oil seal-2.5L engine


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the seal from the retainer.
  2.  

To install:
  1. Lightly coat the seal outer diameter with Loctite® Stud N' Bearing Mount, or equivalent.
  2.  
  3. Install the seal to the retainer.
  4.  
  5. If the retainer was removed, thoroughly clean and dry the retainer to block sealing surfaces and install a new gasket or apply silicone sealer and install the retainer. Install the pan, if it was removed.
  6.  
  7. Install the flywheel or flexplate and the transmission or transaxle.
  8.  
  9. Connect the negative battery cable and check for leaks.
  10.  

3.9L and 5.2L Engines

See Figures 3, 4, 5, 6 and 7

  1. Raise the vehicle and support it safely.
  2.  
  3. Drain the engine oil. Remove the oil pan and oil pump.
  4.  
  5. Remove the rear main bearing cap.
  6.  



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Fig. Fig. 3: A modified rear main bearing rope seal-V6 and 5.2L V8 engines



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Fig. Fig. 4: Apply sealer to the indicated areas before installing the oil pan-V6 and 5.2L V8 engines

  1. Remove the lower seal from the cap.
  2.  
  3. To remove the upper rope seal, use Oil Seal Remover and Installer Kit KD-492, or equivalent, following the instructions provided with the tool.
  4.  

To install:
  1. Wipe the crankshaft surface clean and coat it lightly with oil.
  2.  
  3. Use Oil Seal Remover and Installer Kit KD-492 or equivalent to install the upper rope seal. Trim the ends of the upper seal to eliminate frayed ends.
  4.  



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Fig. Fig. 5: Use the special tool shown to install the upper and lower oil seals-V6 and V8 engines



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Fig. Fig. 6: Trim the oil seal to eliminate the frayed ends

  1. Install the lower rope seal in the main cap so that both ends protrude. Use tool C-3511, or equivalent, to seat the seal in its groove. Cut off the portions of the seal that extend above the cap on both sides and install the end seals to the cap.
  2.  



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Fig. Fig. 7: Position the lower rope seal and end seals in the rear main bearing cap-5.2L engine

  1. Install the main cap to the block and tighten the bolts to 85 ft. lbs. (115 Nm).
  2.  
  3. Install the oil pan and fill the engine with the proper amount of oil.
  4.  
  5. Connect the negative battery cable and check for leaks.
  6.  

5.9L Engine

See Figures 5 and 6

  1. Raise the vehicle and support safely. Drain the engine oil. Remove the oil pan and oil pump.
  2.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the rear main bearing cap.
  2.  
  3. Remove the lower seal from the cap.
  4.  
  5. To remove the upper seal, press on one end of the seal with a small blunt tool, rotate the crankshaft slightly and pull out the other end of the seal.
  6.  

To install:
  1. Wipe the crankshaft surface clean and coat it lightly with oil.
  2.  
  3. When installing the upper seal, hold the seal (with the paint stripe to the rear) tightly against the crankshaft and rotate the crankshaft while sliding the seal into the groove. If any rubber has peeled off of the back of the new seal, do not use it; it will leak.
  4.  
  5. When installing the lower rubber seal, make sure the paint stripe is positioned to the rear and place a drop of sealer next to both ends of the seal.
  6.  
  7. Install the main cap to the block and tighten the bolts to 85 ft. lbs. (115 Nm).
  8.  
  9. Install the oil pump and pan and fill the engine with the proper amount of oil.
  10.  
  11. Connect the negative battery cable and check for leaks.
  12.  

8.0L Engine

See Figure 8

  1. Remove the transmission.
  2.  
  3. Remove the oil pan.
  4.  
  5. Remove the rear seal retainer. Discard the oil seal and gasket.
  6.  

To install:
  1. Wash all parts in a safe solvent and inspect carefully for wear or damage.
  2.  
  3. Position the new seal in the retainer.
  4.  



Click image to see an enlarged view

Fig. Fig. 8: Exploded view of the rear crankshaft main seal assembly-V10 engine

  1. Position the retainer and oil seal over the crankshaft using special tool No. 6687, or equivalent. Install the bolts, tightening them to 16 ft. lbs. (22 Nm).
  2.  
  3. Check that the seal surface is within 0.020 in. (0.508mm) full indicator movement relative to the rear face of the crankshaft. If it is out of limits, use a soft face hammer to gently tap the high side into the retainer.
  4.  
  5. Seal the split line with a small amount of a suitable silicon rubber adhesive sealant.
  6.  
  7. Install the oil pan.
  8.  
  9. Install the transmission.
  10.  

Diesel Engine

See Figures 9, 10 and 11

The rear crankshaft seal is mounted in a housing that is bolted to the rear of the block. A double-lipped Teflon® seal is used.

  1. Disconnect the negative battery cable.
  2.  



Click image to see an enlarged view

Fig. Fig. 9: Exploded view of the rear seal housing and gasket-diesel engine

  1. Remove the transmission.
  2.  
  3. Remove the clutch cover and plate, if equipped.
  4.  
  5. Remove the flywheel.
  6.  



Click image to see an enlarged view

Fig. Fig. 10: Use a slide hammer to remove the rear main oil seal-diesel engine



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Fig. Fig. 11: Install and align the rear crankshaft seal with the special tool as shown-diesel engine

  1. Drill two 0.118 in. (3mm) holes 180° apart into the seals. Be extremely careful not to drill against the crankshaft.
  2.  
  3. Insert two No. 10 sheet metal screws and, using a slide hammer, remove the rear seal.
  4.  

To install:
  1. Thoroughly clean and dry the crankshaft surface. Do not oil the crankshaft or seal prior to installation or the seal will leak.
  2.  
  3. Install the seal pilot included in the replacement seal kit, on the crankshaft. Push the seal on the pilot and crankshaft. Remove the pilot.
  4.  
  5. If the new seal has a rubber outer diameter, lubricate it with soapy water. If the seal does not have a rubber outer diameter, use Loctite® 277, or equivalent on the outer diameter.
  6.  
  7. Use the alignment tool to install the seal to the proper depth in the housing. Drive the seal in gradually and evenly until the alignment tool stops against the housing.
  8.  

 
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