Pan-Engine Oil-AWD: Removal

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: Engine Cover

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1 - Engine Cover

2 - Attaching Studs

Disconnect the negative battery cable.
Remove the engine cover (1).

Remove the intake manifold. (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL) .

Fig 2: Engine Lift Fixture And Adapter

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1 - Bolts

2 - Engine Lift Fixture

3 - Adapter Bolt

4 - Adapter

5 - Adapter Nut

Install engine lift fixture (2) special tool # 8984 and adapter # 8984-UPD. Never use air tools when installing fasteners to engine.
Raise vehicle.

Fig 3: Front Belly Pan
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Remove the belly pan (2) (Refer to BODY/EXTERIOR/BELLY PAN - REMOVAL) .
Remove both left and right side engine mount to frame fasteners.
Drain engine oil and remove the oil filter.

Fig 4: AWD Gear Mounting Bolts
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Unbolt (2,3,4) and lower the steering rack (1) from the mounts. Do not remove P/S hoses, tie rod ends or disconnect steering column.
Remove the engine oil dipstick and tube from the oil pan.

Remove the left and right side exhaust at the manifolds. (Refer to EXHAUST SYSTEM/CATALYTIC CONVERTER - REMOVAL) .

Fig 5: Left Drive Axle and Intermediate Shaft

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1 - FASTENER

2 - LEFT FRONT DRIVE AXLE

3 - INTERMEDIATE SHAFT HOUSING

4 - OIL PAN

Mark the front driveshaft to the flange at both ends to ensure correct installation.
Remove front drive shaft fasteners from the differential and transfer case. Remove the driveshaft from the vehicle.

Remove the left (2) and right front drive axles.

Fig 6: Front Drive Axle Housing

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1 - BRACKET

2 - BOLT

3 - DRIVE AXLE HOSING

4 - FRONT DRIVE SHAFT SHIELD

Remove the differential support bracket (1) from the differential to the engine block.

Fig 7: Front Drive Axle Assembly

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1 - LEFT FRONT DRIVE AXLE

2 - INTERMEDIATE SHAFT

3 - OIL PAN

4 - FRONT DRIVE AXLE HOUSING

Unbolt the differential (4) from the oil pan (3).

Rotate the differential (4) so the drive flange is facing forward and the oil pan side is facing up. Remove the differential out through the opening at the rear of the cradle.

Fig 8: Front Drive Axle Assembly

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1 - LEFT FRONT DRIVE AXLE

2 - INTERMEDIATE SHAFT

3 - OIL PAN

4 - FRONT DRIVE AXLE HOUSING

Remove the intermediate shaft (2) from the oil pan (3).
Lower the vehicle.
Install engine support fixture special tool # 8534. Do not attempt to fasten fixture to vehicle body, or attach the third support leg to the radiator support.
Raise engine using special tool # 8534 and #8984 to provide clearance to remove oil pan.
Raise vehicle.
NOTE: Do not pry on oil pan or oil pan gasket. Gasket is integral to engine windage tray and does not come out with oil pan.

Fig 9: Oil Pan Torque Sequence
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NOTE: The horizontal M10 fasteners are 5 mm longer in length, and must be reinstalled in original locations.
Remove the M10 fasteners (vertical and horizontal) from the rear of the oil pan to the transmission and engine.
Remove the oil pan mounting bolts and oil pan.
NOTE: When the oil pan is removed, a new oil pan gasket/windage tray assembly must be installed. The old gasket cannot be reused.
Discard the integral windage tray and gasket and replace.