Pan-Engine Oil-AWD: Installation: Pan-Oil-Install-AWD

WARNING: This page is about a different car, the 2008 Dodge Magnum, 2008 Dodge Charger, and 2008 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: T-Joint RTV Sealant Application

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1 - Front Cover T-Joints

2 - Rear Oil Retainer T-Joints

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.
Apply Mopar® Engine RTV at the 4 T- joints (1,2).

Fig 2: Oil Pan Torque Sequence
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NOTE: When the oil pan is removed, a new oil pan gasket/windage tray assembly must be installed. The old gasket cannot be reused.
Install a new oil pan gasket/windage tray assembly.
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.
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.).
Using the following torque sequence, torque the M10 oil pan fasteners to 54 N.m (39 ft. lbs.).

Using the following torque sequence, torque the M6 oil pan fasteners to 12 N.m (106 in. lbs.).

Fig 3: Front Drive Axle Assembly

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1 - LEFT FRONT DRIVE AXLE

2 - INTERMEDIATE SHAFT

3 - OIL PAN

4 - FRONT DRIVE AXLE HOUSING

Install the intermediate shaft (2) to the oil pan (3). Torque fasteners to 28 N.m (21 ft. lbs).

Fig 4: Front Drive Axle Assembly

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1 - LEFT FRONT DRIVE AXLE

2 - INTERMEDIATE SHAFT

3 - OIL PAN

4 - FRONT DRIVE AXLE HOUSING

Install the front differential through the opening at the rear of the cradle, and attach to the oil pan.

Fasten the differential (4) to the oil pan (3) Torque to 65 N.m (48 ft. lbs).

Fig 5: Front Drive Axle Housing

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1 - BRACKET

2 - BOLT

3 - DRIVE AXLE HOSING

4 - FRONT DRIVE SHAFT SHIELD

Install the differential support bracket (1) to the differential and the engine block.

Fig 6: Left Drive Axle And Intermediate Shaft

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1 - FASTENER

2 - LEFT FRONT DRIVE AXLE

3 - INTERMEDIATE SHAFT HOUSING

4 - OIL PAN

Install the left (2) and right front drive axles. Refer to INSTALLATION .
Install front drive shaft into the differential and transfer case. Refer to INSTALLATION .
Install the engine oil dipstick and tube.

Fig 7: AWD Gear Mounting Bolts
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Install the steering gear (1). Refer to INSTALLATION .
Lower the engine into mounts using special tool # 8534.

Install both the left and right side engine mount studs and nuts.

Fig 8: Engine Lift Fixture And Adapter

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1 - Bolts

2 - Engine Lift Fixture

3 - Adapter Bolt

4 - Adapter

5 - Adapter Nut

Remove special tool # 8534.
Remove special tool # 8984 (2,4).
Install the intake manifold. See INSTALLATION .
Install the left and right side exhaust at the manifolds. Refer to INSTALLATION .
Fill engine oil.
Install oil filter, if removed.
Reconnect the negative battery cable.
Start engine and check for leaks.

Fig 9: Engine Cover
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1 - Engine Cover

2 - Attaching Studs
Install the engine cover (1).

Fig 10: Front Belly Pan
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Install the belly pan (2). Refer to INSTALLATION .