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PAN, Oil, AWD: Removal: Removal

WARNING: This page is about a different variant/trim than selected.
Fig 1: Engine Cover
GC0081749Courtesy of CHRYSLER LLC
1 - Engine Cover
2 - Attaching Studs
  1. Disconnect the negative battery cable.
  2. Remove the engine cover (1).
  3. Remove the intake manifold. See Engine/Manifolds/MANIFOLD, Intake - Removal .
    Fig 2: Engine Lift Fixture & Adapter
    GC0095579Courtesy of CHRYSLER LLC
    1 - Bolts
    2 - Engine Lift Fixture
    3 - Adapter Bolt
    4 - Adapter
    5 - Adapter Nut
  4. Install engine lift fixture (2) special tool 8984A and adapter 8984-UPD. Never use air tools when installing fasteners to engine. 
  5. Raise vehicle.
    Fig 3: Front Belly Pan
    GC0081802Courtesy of CHRYSLER LLC
  6. Remove the belly pan (2). Refer to Body/Exterior/BELLY PAN - Removal .
  7. Remove both left and right side engine mount to frame fasteners.
  8. Drain engine oil and remove the oil filter.
    Fig 4: AWD Gear Mounting Bolts
    GC0081803Courtesy of CHRYSLER LLC
  9. 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. 
  10. Remove the engine oil dipstick and tube from the oil pan.
  11. Remove the left and right side exhaust at the manifolds. Refer to Exhaust System/CONVERTER, Catalytic - Removal .
    Fig 5: Left Drive Axle And Intermediate Shaft
    GC0081804Courtesy of CHRYSLER LLC
    1 - FASTENER
    2 - LEFT FRONT DRIVE AXLE
    3 - INTERMEDIATE SHAFT HOUSING
    4 - OIL PAN
  12. Mark the front driveshaft to the flange at both ends to ensure correct installation.
  13. Remove front drive shaft fasteners from the differential and transfer case. Remove the driveshaft from the vehicle.
  14. Remove the left (2) and right front drive axles.
    Fig 6: Front Drive Axle Housing
    GC0081805Courtesy of CHRYSLER LLC
    1 - BRACKET
    2 - BOLT
    3 - DRIVE AXLE HOSING
    4 - FRONT DRIVE SHAFT SHIELD
  15. Remove the differential support bracket (1) from the differential to the engine block.
    Fig 7: Front Drive Axle Assembly
    GC0095580Courtesy of CHRYSLER LLC
    1 - LEFT FRONT DRIVE AXLE
    2 - INTERMEDIATE SHAFT
    3 - OIL PAN
    4 - FRONT DRIVE AXLE HOUSING
  16. Unbolt the differential (4) from the oil pan (3).
  17. 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
    GC0095580Courtesy of CHRYSLER LLC
    1 - LEFT FRONT DRIVE AXLE
    2 - INTERMEDIATE SHAFT
    3 - OIL PAN
    4 - FRONT DRIVE AXLE HOUSING
  18. Remove the intermediate shaft (2) from the oil pan (3).
  19. Lower the vehicle.
  20. Install engine support fixture special tool 8534B. Do not attempt to fasten fixture to vehicle body, or attach the third support leg to the radiator support. 
  21. Raise engine using special tool 8534B and 8984A to provide clearance to remove oil pan.
  22. 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
    GC0095581Courtesy of CHRYSLER LLC
    NOTE: The horizontal M10 fasteners are 5 mm longer in length, and must be reinstalled in original locations.
  23. Remove the M10 fasteners (vertical and horizontal) from the rear of the oil pan to the transmission and engine.
  24. 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.
  25. Discard the integral windage tray and gasket and replace.
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