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Pan-Engine Oil-AWD: Installation

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: T-Joint RTV Sealant Application
GC0004008Courtesy of DAIMLERCHRYSLER CORP.
1 - Front Cover T-Joints
2 - Rear Oil Retainer T-Joints
  1. Clean the oil pan gasket mating surface of the block and oil pan.
    NOTE: Mopar® Engine RTV must be applied to the 4 T-joints, (area where front cover, rear retainer, block, and oil pan gasket meet). The bead of RTV should cover the bottom of the gasket. This area is approximately 4.5 mm x 25 mm in each of the 4 T-joint locations.
  2. Apply Mopar® Engine RTV at the 4 T- joints (1,2).
    Fig 2: Oil Pan Torque Sequence
    GC0004016Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: When the oil pan is removed, a new oil pan gasket/windage tray assembly must be installed. The old gasket cannot be reused.
  3. Install a new oil pan gasket/windage tray assembly.
  4. If removed, reinstall the oil pump pickup tube with new o-ring. Tighten tube to pump fasteners to 28 N.m (250 in. lbs.).
    NOTE: The horizontal M10 fasteners are 5 mm longer in length, and must be reinstalled in original locations.
    NOTE: New M6 fasteners must be used when reinstalling the oil pan. Do not reuse the old M6 fasteners.
  5. Align the rear of the oil pan with the rear face of the engine block, and install the M10 and M6 oil pan fasteners finger tight. Using the following torque sequence, torque the M6 mounting bolts to 5 N.m (44 in.lbs.).
  6. Using the following torque sequence, torque the M10 oil pan fasteners to 54 N.m (39 ft.lbs.).
  7. Using the following torque sequence, torque the M6 oil pan fasteners to 12 N.m (106 in.lbs.).
    Fig 3: FRONT DRIVE AXLE ASSEMBLY
    GC0015481Courtesy of DAIMLERCHRYSLER CORP.
    1 - LEFT FRONT DRIVE AXLE
    2 - INTERMEDIATE SHAFT
    3 - OIL PAN
    4 - FRONT DRIVE AXLE HOUSING
  8. Install the intermediate shaft (2) to the oil pan (3). Torque fasteners to 28N.m (21ft. lbs).
    Fig 4: FRONT DRIVE AXLE ASSEMBLY
    GC0015481Courtesy of DAIMLERCHRYSLER CORP.
    1 - LEFT FRONT DRIVE AXLE
    2 - INTERMEDIATE SHAFT
    3 - OIL PAN
    4 - FRONT DRIVE AXLE HOUSING
  9. Install the front differential through the opening at the rear of the cradle, and attach to the oil pan.
  10. Fasten the differential (4) to the oil pan (3) Torque to 65 N.m (48 ft. lbs).
    Fig 5: FRONT DRIVE AXLE HOUSING
    GC0015482Courtesy of DAIMLERCHRYSLER CORP.
    1 - BRACKET
    2 - BOLT
    3 - DRIVE AXLE HOSING
    4 - FRONT DRIVE SHAFT SHIELD
  11. Install the differential support bracket (1) to the differential and the engine block.
    Fig 6: LEFT DRIVE AXLE AND INTERMEDIATE SHAFT
    GC0015483Courtesy of DAIMLERCHRYSLER CORP.
    1 - FASTENER
    2 - LEFT FRONT DRIVE AXLE
    3 - INTERMEDIATE SHAFT HOUSING
    4 - OIL PAN
  12. Install the left (2) and right front drive axles. (Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION) .
  13. Install front drive shaft into the differential and transfer case. (Refer to DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT - INSTALLATION)
  14. Install the engine oil dipstick and tube.
    Fig 7: AWD GEAR MOUNTING BOLTS
    GC0015485Courtesy of DAIMLERCHRYSLER CORP.
  15. Install the steering gear (1). (Refer to STEERING/GEAR - INSTALLATION) .
  16. Lower the engine into mounts using special tool # 8534.
  17. Install both the left and right side engine mount studs and nuts.
    Fig 8: Engine Lift Fixture And Adapter
    GC0015474Courtesy of DAIMLERCHRYSLER CORP.
    1 - Bolts
    2 - Engine Lift Fixture
    3 - Adapter Bolt
    4 - Adapter
    5 - Adapter Nut
  18. Remove special tool # 8534.
  19. Remove special tool # 8984 (2,4).
  20. Install the intake manifold. (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION) .
  21. Install the left and right side exhaust at the manifolds. (Refer to EXHAUST SYSTEM/CATALYTIC CONVERTER - INSTALLATION) .
  22. Fill engine oil.
  23. Install oil filter, if removed.
  24. Reconnect the negative battery cable.
  25. Start engine and check for leaks.
    Fig 9: Engine Cover
    GC0004015Courtesy of DAIMLERCHRYSLER CORP.
    1 - Engine Cover
    2 - Attaching Studs
  26. Install the engine cover (1).
    Fig 10: FRONT BELLY PAN
    GC0015484Courtesy of DAIMLERCHRYSLER CORP.
  27. Install the belly pan (2) (Refer to BODY/EXTERIOR/BELLY PAN - INSTALLATION) .
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