Chrysler Full-Size Trucks 1997-2000 Repair Guide

Rear Main Seal

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REMOVAL & INSTALLATION



2.5L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Drain the engine oil.
  6.  


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 flywheel or converter drive plate. Discard the old bolts.
  2.  
  3. Pry out the seal from around the crankshaft flange, taking care not to scratch the crank.
  4.  

To install:

  1. Clean the contact areas.
  2.  
  3. Coat the outer lip of the replacement seal with clean oil.
  4.  
  5. Position the seal and drive the seal in until flush with the engine block.
  6.  
  7. The felt lip must be located inside the flywheel mounting surface.
  8.  
  9. Use new bolts on the flywheel or converter plate. Tighten to 50 ft. lbs. (68 Nm).
  10.  

3.9L, 5.2L, 5.9L Gasoline Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Drain the engine oil.
  6.  


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 oil pan.
  2.  
  3. Remove the oil pump.
  4.  
  5. Loosen all the main bearing cap bolts, thereby lowering the crankshaft slightly but not to exceed 1 / 32 in. (0.8mm).
  6.  
  7. Remove the rear main bearing cap, and remove the oil seal from the bearing cap and cylinder block. On the block half of the seal use a seal removal tool, or install a small metal screw in one end of the seal, and pull on the screw to remove the seal. Exercise caution to prevent scratching or damaging the crankshaft seal surfaces.
  8.  
  9. Remove the oil seal retaining pin from the bearing cap (if equipped). The pin is not used with the split-lip seal.
  10.  



Click image to see an enlarged view

Fig. Removing the split rubber oil seal

To install:



Click image to see an enlarged view

Fig. Assembled view of the rear main bearing cap and seals

  1. Thoroughly clean the seal groove in the cap and block.
  2.  
  3. Dip the split lip-type seal halves in clean engine oil.
  4.  
  5. If the replacement seals are marked with white paint, the marks must face the REAR of the engine.
  6.  
  7. Carefully install the upper seal (cylinder block) into its groove with undercut side of the seal (rubber type) toward the FRONT of the engine, by rotating it on the seal journal of the crankshaft until approximately 3 / 8 in. (9.5mm) protrudes below the parting surface.
  8.  
  9. On rope type, pull into position with the seal installing tool. Be sure no rubber has been shaved from the outside diameter of the seal by the bottom edge of the groove. Do NOT allow oil to get on the sealer area.
  10.  
  11. Tighten the main bearing cap bolts.
  12.  
  13. On the rope type seal, trim the upper seal ends flush with the block surface. Install the lower seal (rubber type) in the rear main bearing cap under undercut side of seal toward the FRONT of the engine, allow the seal to protrude approximately 3 / 8 in. (9.5mm) above the parting surface to mate with the upper seal when the cap is installed. With rope type seals, press the seal full and firmly into the cap groove. Trim the ends flush with the cap.
  14.  
  15. Install the side seals into the bearing cap. Apply an even 1 / 16 in. (1.6mm) bead of RTV silicone sealer at the bearing cap to block joint to provide oil pan end sealing.
  16.  



Click image to see an enlarged view

Fig. Oil pan end main bearing cap sealer points


NOTE
This sealer sets up in 15 minutes.

  1. Install the rear main bearing cap.
  2.  
  3. Tighten the cap bolts to 85 ft. lbs. (115 Nm).
  4.  
  5. Install the oil pump.
  6.  
  7. Install the oil pan.
  8.  
  9. Refill the engine oil.
  10.  


WARNING
Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

  1. Start the engine and check for leaks.
  2.  
  3. Turn the engine off, recheck the engine oil.
  4.  
  5. Lower the vehicle.
  6.  

4.7L Engine
  1. Remove the transmission.
  2.  
  3. Remove the flexplate.
  4.  
  5. Pry out the old seal.
  6.  
  7. To install, drive a new seal in with a suitable driver.
  8.  

8.0L Engine
  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. 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

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.  
  3. Remove the transmission.
  4.  
  5. Remove the clutch cover and plate, if equipped.
  6.  
  7. Remove the flywheel.
  8.  



Click image to see an enlarged view

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

  1. Drill two 0.118 in. (3mm) holes 180º 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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