GrandCaravan 2008

Rear Main Seal

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Removal & Installation



3.3L & 3.8L Engines

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


NOTE
Any time the rear crank oil seal has been removed from the engine block, a new seal assembly must be installed. Do not re-use a rear crank oil seal assembly once it has been removed.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the transaxle. Refer to Automatic Transaxle Assembly, removal & assembly.
  4.  
  5. Remove the flexplate. Refer to Flexplate, removal & installation.
  6.  
  7. Remove the oil seal retainer bolts (1).
  8.  
  9. Remove the oil seal retainer (2).
  10.  
  11. Clean the engine block and the retainer of oil and gasket material. Make sure the surfaces are clean and free of oil.

    Click image to see an enlarged view

    Fig. Remove the rear oil seal retainer (2)-3.3L and 3.8L engines

  12.  

To install:


WARNING
Before installing a new rear oil seal assembly, ensure that the plastic installation sleeve is present in the seal assembly. The new seal cannot be properly installed without the plastic installation sleeve, and if the seal assembly is installed without it, oil leakage will result.

  1. Remove any original sealer, oil, or debris from the rear oil seal retainer assembly mounting area.
  2.  
  3. Place a bead (approximately 1 / 4 inch diameter) of MOPAR® Engine RTV GEN II in the lower corners of the rear crankshaft oil seal retainer mounting surface, where the seal retainer meets the oil pan (the T-Joint).
  4.  
  5. Place a bead (approximately 1 / 4 inch diameter) of MOPAR® Engine RTV GEN II around the inside edge of the rear crankshaft oil seal retainer assembly recess in the engine block.
  6.  
  7. Place the rear crankshaft oil seal assembly over the rear crankshaft flange. Do not press the seal assembly over the rear crankshaft flange at this time.
  8.  
  9. Using both hands, one on each side of the rear crankshaft flange, press the rear crankshaft oil seal over the rear crankshaft flange.
  10.  
  11. Ensure that the extruded dowels in the rear crankshaft oil seal are seated in the locating holes in the rear of the engine block.
  12.  
  13. Install the 5 rear crankshaft oil seal fasteners. Do not tighten at this time.
  14.  
  15. Remove and discard the plastic installation sleeve.
  16.  
  17. Tighten the 5 rear crankshaft oil seal fasteners to 105 inch lbs. (12 Nm).
  18.  
  19. Install the flexplate. Refer to Flexplate, removal & installation.
  20.  
  21. Install the transaxle. Refer to Automatic Transaxle Assembly, removal & assembly.
  22.  

4.0L Engine

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the transaxle. Refer to Automatic Transaxle Assembly, removal & assembly.
  4.  
  5. Remove the flexplate. Refer to Flexplate, removal & installation.
  6.  
  7. Remove the 7 upper bolts (1) holding the rear main seal carrier (3) to the engine block.
  8.  
  9. Remove the 2 lower nuts (2) holding the rear main seal carrier (3) to the engine block.
  10.  
  11. Remove the rear main seal carrier (3) from the engine block and oil pan.
  12.  
  13. Clean the sealant residue from the engine block and oil pan.
    NOTE
    The seal retainer gasket is bonded to the retainer and must be replaced as an assembly.



    Click image to see an enlarged view

    Fig. Remove the rear oil seal carrier (3)-4.0L engine

  14.  

To install:


NOTE
If a burr or scratch is present on the crankshaft edge (chamfer), clean the surface using 400 grit sand paper to prevent seal damage during installation. Make sure the rear crankshaft oil seal surface is clean and free of any abrasive materials.


WARNING
The rear crankshaft oil seal and retainer are an assembly. DO NOT separate the seal protector from the rear crankshaft oil seal before installation on the engine. Damage to the seal lip will occur if the seal protector is removed and installed prior to installation on the engine.

  1. Apply engine oil to the crankshaft seal surface.
  2.  
  3. If the seal protector (1) is missing or was accidentally dislodged, go to Step 3. Otherwise, carefully position the oil seal retainer assembly (3), and the seal protector (1) on the crankshaft and push firmly into place on the engine block (during this step, the seal protector will be pushed from the rear oil seal assembly as a result of installing the rear oil seal). Hand tighten the rear oil seal fasteners, and go to Step 4.
    NOTE
    The seal lip (2) must uniformly curl inward toward the engine on the crankshaft (1).



    Click image to see an enlarged view

    Fig. Rear oil seal retainer assembly shown with the seal protector intact-4.0L engine



    Click image to see an enlarged view

    Fig. The seal lip (2) must uniformly curl inward toward the engine on the crankshaft (1)-4.0L engine

  4.  
  5. Using the chamfered seal guide from Special Tool 6926, insert the tapered end (1) into the transaxle side of the rear crankshaft oil seal assembly (2), and push the seal guide through the seal assembly. This will ensure that the seal lip is positioned toward the engine when the seal assembly is installed. When the seal lip is correctly positioned, go to Step 2.
    NOTE
    The following steps must be performed to prevent oil leaks at the sealing joints.



    Click image to see an enlarged view

    Fig. Using the chamfered seal guide from Special Tool 6926 to push the seal guide through the seal assembly-4.0L engine

  6.  
  7. Attach Special Tools 8225 (2) to the pan rail using the oil pan fasteners.
    NOTE
    Special Tools 8225 (2), are used to assist with the fit of the flush mount rear main seal retainer. The notch on the tool should be located away from the seal retainer.

  8.  
  9. While applying firm pressure to the seal retainer against Special Tools 8225 (2), tighten the seal retainer screws to 105 inch lbs. (12 Nm).
  10.  
  11. Remove Special Tools 8225 (2).
    NOTE
    Make sure that the seal flange is flush with the block oil pan sealing surface.



    Click image to see an enlarged view

    Fig. Using Special Tool 8225 to assist with the fit of the flush mount rear main seal retainer-4.0L engine

  12.  
  13. Install the oil pan. Tighten the 6mm fasteners to 105 inch lbs. (12 Nm) and the 8mm fasteners to 250 inch lbs. (28 Nm).
  14.  
  15. Install the flexplate. Refer to Flexplate, removal & installation.
  16.  
  17. Install the transaxle. Refer to Automatic Transaxle Assembly, removal & assembly.
  18.  

 
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