Jeep Wagoneer/Commando/Cherokee 1984-1998

Crankshaft Main Oil Seal

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Removal & Installation



2.1L Diesel Engine

If the end seals are being replaced, remove the engine and place it on an engine stand. If the side seals are being replaced, remove the oil pan. It is advisable to replace the end seals if the side seals are leaking.

FRONT END MAIN SEAL

See Figure 1

  1. Remove the engine.
  2.  
  3. Remove the timing belt and sprockets.
  4.  
  5. Using a sharp awl, punch a hole in the seal and pry it out of its bore.
  6.  
  7. Thoroughly clean the bore.
  8.  



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Fig. Fig. 1: Front seal installation

  1. Coat the outer edge of the new seal with sealer and the inner sealing surface with clean engine oil.
  2.  
  3. Using a seal driver, drive the new seal into place.
  4.  
  5. Install the timing belt and sprockets, and all other related parts.
  6.  
  7. Install the engine.
  8.  

REAR END MAIN SEAL

See Figure 2

  1. Remove the engine.
  2.  
  3. Remove the flywheel.
  4.  
  5. Using a sharp awl, punch a hole in the seal and pry it out of its bore.
  6.  
  7. Thoroughly clean the bore.
  8.  



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Fig. Fig. 2: Rear seal installation

  1. Coat the outer edge of the new seal with sealer and the inner sealing surface with clean engine oil.
  2.  
  3. Using a seal driver, drive the new seal into place.
  4.  
  5. Install the flywheel.
  6.  
  7. Install the engine.
  8.  

SIDE SEALS

See Figures 3 and 4

Depending on working clearance, it may be necessary to remove the engine.

  1. Remove the oil pan.
  2.  
  3. Remove the main bearing cap.
  4.  
  5. Remove the side seals.
  6.  
  7. Thoroughly clean the seal surfaces in the block and cap.
  8.  
  9. Install the cap.
  10.  
  11. Measure the width of the seal bore.
  12.  



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Fig. Fig. 3: Measure the side bore

  1. If the seal bore is 0.196 in. (5mm) or less, use a 0.20 in. (5.1mm) thick seal; if it is more than 0.196 in. (5mm), use a 0.25 in. (5.4mm) thick seal.
  2.  
  3. Remove the bearing cap.
  4.  
  5. Insert the proper side seals in the cap grooves with the grooves in the seals facing outward. Each seal should stick out from the cap about 0.007 in. (0.2mm).
  6.  
  7. Lightly coat the seals with clean engine oil.
  8.  
  9. Cover the length of each seal with a strip of aluminum foil and install the cap and seals in the block. Don't install the cap bolts. Remove the foil.
  10.  



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Fig. Fig. 4: Cover the seals with foil

  1. Measure the side seal protrusion above the cap. Protrusion should be greater than 0.027 in. (0.7mm).
  2.  
  3. Tighten the bearing cap bolts to 72 ft. lbs. (98 Nm).
  4.  
  5. Cut the side seals to within 0.019-0.027 in. (0.5-0.7mm) protrusion.
  6.  
  7. Install the oil pan.
  8.  

2.5L Engine

See Figure 5

  1. Remove the transmission.
  2.  
  3. Remove the flywheel.
  4.  
  5. Pry out the seal from around the crankshaft flange.
  6.  



Click image to see an enlarged view

Fig. Fig. 5: 2.5L rear main seal

To install:
  1. Coat the inner lip of the new seal with clean engine oil.
  2.  
  3. Gently tap the new seal into place, flush with the block, using a rear main seal installer tool.
  4.  

The felt lip must be located inside the flywheel mounting surface. If the lip is not positioned correctly, the flywheel could damage the seal.

  1. Install all parts in reverse order of removal.
  2.  

2.8L Engine

The General Motors built 2.8L will have one of two different rear main seal assemblies: either a 1-piece or 2-piece seal. The 2-piece type requires removal of the rear main bearing cap for servicing. The wide, 1-piece seal, used on later model engines, requires the removal of the transmission and flywheel.

2-PIECE

See Figures 6 and 7

  1. Remove the oil pan and pump.
  2.  
  3. Remove the rear main bearing cap.
  4.  
  5. Gently pack the upper seal into the groove approximate 1 / 4 in. (6mm) on each side.
  6.  
  7. Measure the amount the seal was driven in on one side and add 1 / 16 in. (1.5mm). Cut this length from the old lower cap seal. Be sure to get a sharp cut. Repeat for the other side.
  8.  
  9. Place the piece of cut seal into the groove and pack the seal into the block. Do this for each side.
  10.  

GM makes a guide tool (J-29114-1) which bolts to the block via an oil pan bolt hole, and a packing tool (J29114-2) which are machined to provide a built-in stop for the installation of the short cut pieces. Using the packing tool, work the short pieces of seal onto the guide tool, then pack them into the block with the packing tool.

  1. Install a new lower seal in the rear main cap.
  2.  
  3. Install a piece of Plastigage® or the equivalent on the bearing journal. Install the rear cap and tighten to 70 ft. lbs. (95 Nm). Remove the cap and check the gauge for bearing clearance. If out of specification, the ends of the seal may be frayed or not flush, preventing the cap from proper sealing. Correct as required.
  4.  



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Fig. Fig. 6: Apply RTV sealer as shown



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Fig. Fig. 7: Installing the lower seal in the cap

  1. Clean the journal, and apply a thin film of RTV silicone sealer to the mating surfaces of the cap and block. Do not allow any sealer to get onto the journal or bearing. Install the bearing cap and tighten to 70 ft. lbs. (95 Nm). Install the pan and pump.
  2.  

1-PIECE

See Figures 8 and 9

  1. Remove transmission and flywheel.
  2.  
  3. Using an appropriate tool, pry the seal from around the crankshaft flange. Insert the prytool under the seal dust lip and pry up and out.
  4.  



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Fig. Fig. 8: Removing the one piece seal

DO NOT allow the prytool to contact the crankshaft journal surface.

To install:
  1. Clean and lubricate the inner and outer surfaces of the replacement seal thoroughly with engine oil.
  2.  



Click image to see an enlarged view

Fig. Fig. 9: Rear seal installation tool

  1. Install the seal on the installation tool (J-34686). Ensure the seal dust lip faces the collar of the installation tool. Seat the seal firmly against the collar of the tool.
  2.  
  3. Align the dowel pin of the tool with the dowel pin hole and tighten tool to crankshaft flange with attaching bolts. Tighten bolts to 24-36 ft. lbs. (33-49 Nm).
  4.  
  5. Install the seal by tightening the T-handle of the tool until the seal is firmly seated against the block and bearing cap.
  6.  
  7. Fully retract the T-handle of the tool. Remove the attaching bolts and tool. Verify the seal is properly seated.
  8.  
  9. Install the flywheel and transmission.
  10.  

4.0L Engine

See Figure 10

  1. Remove the transmission.
  2.  
  3. Remove the flywheel or flexplate.
  4.  
  5. Pry the seal out from around the crankshaft flange.
  6.  
  7. Remove the rear main bearing cap and wipe clean the cap and crankshaft seal surfaces.
  8.  



Click image to see an enlarged view

Fig. Fig. 10: Rear main seal installation on the 4.0L

To install:
  1. Apply a thin coat of engine oil to the seal surfaces of the cap and crankshaft.
  2.  
  3. Coat the lip of each seal half with clean engine oil.
  4.  
  5. Position the upper seal half in the block. The lip of the seal faces the front of the engine.
  6.  
  7. Coat both side of the lower seal's end tabs with RTV silicone gasket material. Don't get any on the seal lip.
  8.  
  9. Coat the outer, curved surface of the lower seal with soap.
  10.  
  11. Seat the lower seal firmly in the bearing cap recess.
  12.  
  13. Coat both chamfered edges of the bearing cap with RTV silicone gasket material.
  14.  


WARNING
Be careful to avoid getting and RTV material on the bearing cap-to-block mating surfaces! Doing so would change the bearing clearance!

  1. Install the bearing cap.
  2.  
  3. Tighten all the main bearing caps to 80 ft. lbs. (108 Nm).
  4.  

5.2L and 5.9L Engines

See Figures 11 and 12

  1. Remove the oil pan.
  2.  
  3. Remove the oil pump.
  4.  
  5. Remove the rear bearing cap. Remove and discard the old lower seal.
  6.  
  7. Carefully remove and discard the the upper seal.
  8.  
  9. Lightly oil the new upper seal lips with engine oil. To allow ease of installation of the seal, loosen at least 2 main bearing caps.
  10.  
  11. Rotate the new upper seal into the cylinder block being careful not to shave or cut the outer surface of the seal. Install the new seal with the yellow paint facing towards the rear of the engine.
  12.  
  13. Install the new lower seal with the yellow paint facing the rear of the engine.
  14.  



Click image to see an enlarged view

Fig. Fig. 11: Sealant application to the bearing cap



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Fig. Fig. 12: Apply sealant to the bearing cap to block the joint

  1. Apply a 0.20 in. (5mm) drop of Loctite® 518 or equivalent on each side of the rear main bearing cap. Do not allow sealant to contact the seal. Assemble the cap immediately.
  2.  
  3. Install the cap with cleaned and oiled bolts. Alternately tighten all cap bolts to 85 ft. lbs. (115 Nm).
  4.  
  5. Install the oil pump.
  6.  
  7. Install the oil pan.
  8.  

 
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