Oil Pan - AWD

REMOVAL 

1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
2. Disconnect the negative battery cable.
3. Remove the front suspension crossmember. Refer to CROSSMEMBER, FRONT SUSPENSION, REMOVAL AND INSTALLATION .
4. Remove both front half shafts. Refer to REMOVAL AND INSTALLATION .
5. Remove the front propeller shaft. Refer to REMOVAL AND INSTALLATION .
6. Remove the front axle. Refer to REMOVAL AND INSTALLATION .
7. Remove the oil filter and drain the engine oil. Refer to FILTER, ENGINE OIL, REMOVAL AND INSTALLATION .

   Courtesy of CHRYSLER GROUP, LLC

8. Release the wiring and disconnect the electrical connection of the engine oil level sensor (1).

   Courtesy of CHRYSLER GROUP, LLC

9. Remove the screw covers (1) and remove the oil pan to crankcase bolts.

   Courtesy of CHRYSLER GROUP, LLC

10. Remove the gearbox to oil pan bolts (1).

    Courtesy of CHRYSLER GROUP, LLC

11. Loosen the oil pan to the crankcase bolts (1).
12. Using a suitable tool, release the oil pan (2) from the sealant and remove it.

    Courtesy of CHRYSLER GROUP, LLC

13. Remove the screws (1a) and remove the engine oil level sensor (1b).

    Courtesy of CHRYSLER GROUP, LLC

14. Remove the oil supply and return seals (1) from the oil pan flange.
15. Remove sealant residues from the oil pan flange (2) and check the integrity of the locating bushes.
16. Remove sealant residues from the lower engine crankcase flange.

INSTALLATION 

1. Install new oil supply and return seals to the oil pan flange.
2. Install the engine oil level sensor and tighten the screws.

   Courtesy of CHRYSLER GROUP, LLC

3. Clean the oil pan sealing surfaces (1) with isopropyl alcohol in preparation for sealant application.
   CAUTION:

   Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Threebond Engine RTV Sealant may result in engine fluid leakage.

   CAUTION:

   Following the application of Mopar® Threebond Engine RTV Sealant to the gasket surfaces, the components must be assembled within 10 minutes and the attaching fasteners must be tightened to specification within 45 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.

4. Apply a 2 to 3 mm wide bead of Mopar® Threebond Engine RTV Sealant (2) to the oil pan sealing surface. Apply the bead of sealant 0 - 2 mm from the edge of the chamfer (3).
   NOTE:

   The bead of sealant must be uninterrupted.

   Courtesy of CHRYSLER GROUP, LLC

5. Install the engine oil pan (1a) and install the bolts (1b) hand tight.

   Courtesy of CHRYSLER GROUP, LLC

6. Tighten the bolts securing the engine oil pan in the sequence shown in illustration to the proper specification Refer to TORQUE SPECIFICATIONS  .

   Courtesy of CHRYSLER GROUP, LLC

7. Install the gearbox to engine oil pan bolts (1) and tighten to the proper specification Refer to TORQUE SPECIFICATIONS  .

   Courtesy of CHRYSLER GROUP, LLC

8. Install the oil pan to crankcase bolts and tighten to the proper specification Refer to TORQUE SPECIFICATIONS  .
9. Install the screw covers (1) to the oil pan.
10. Connect the electrical connection of the engine oil level sensor electrical connection and engage the wiring.
11. Install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
12. Install the front axle. Refer to REMOVAL AND INSTALLATION .
13. Install the front propeller shaft. Refer to REMOVAL AND INSTALLATION .
14. Install the front half shafts. Refer to REMOVAL AND INSTALLATION .
15. Install the front suspension crossmember. Refer to CROSSMEMBER, FRONT SUSPENSION, REMOVAL AND INSTALLATION .
16. Connect the negative battery cable.
17. Remove the support and lower the vehicle.