Chrysler Full-Size Vans 1989-1998 Repair Guide

Rear Main Seal

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

  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. Fig. 1: Removing the split rubber oil seal

To install:


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Fig. Fig. 2: 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. 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. 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.
  6.  
  7. Tighten the main bearing cap bolts.
  8.  
  9. 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.
  10.  
  11. 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.
  12.  



Click image to see an enlarged view

Fig. Fig. 3: Oil pan end main bearing cap sealer points

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.  

 
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