Upper Oil Pan Replacement

Upper Oil Pan Replacement

Special Tools

J-37228 - Seal Cutter

For equivalent regional tools, refer to Special Tools Special Tools.

Removal Procedure

1. If vehicle is a 4-wheel drive (4WD), remove the front differential carrier. Refer to Differential Carrier Assembly Replacement (2500 4WD) .

2. If vehicle is a 2-wheel drive (2WD), disconnect the relay rod from the pitman arm and idler arm. Refer to Relay Rod Replacement (Dual Rear Wheels or Crew Cab With SRW) Relay Rod Replacement (Dual Rear Wheels or Crew Cab With SRW)Relay Rod Replacement (SRW Except Crew Cab With SRW) Relay Rod Replacement (SRW Except Crew Cab With SRW).

3. Remove the lower oil pan. Refer to Lower Oil Pan Replacement Lower Oil Pan Replacement.

4. Remove the engine flywheel. Refer to Engine Flywheel Replacement Service and Repair.




5. Remove the 2 flywheel housing to upper oil pan bolts (1).




6. Remove the upper oil pan bolts (2, 4).

7. Remove the wiring harness clips (3).

8. Separate the upper oil pan from the engine block using the J-37228 - cutter.

9. Remove the upper oil pan (1).

Installation Procedure




1. Apply a 2-3 mm (0.079-0.118 in) wide by 0.5-1.5 mm (0.02-0.06 in) bead of sealant to the upper oil pan mating surfaces. Refer to Adhesives, Fluids, Lubricants, and Sealers Adhesives, Fluids, Lubricants, and Sealers.

2. Apply a 2-3 mm (0.079-0.118 in) wide by 0.5-1.5 mm (0.02-0.06 in) bead of sealant to the flywheel housing sealing surface. Refer to Adhesives, Fluids, Lubricants, and Sealers Adhesives, Fluids, Lubricants, and Sealers.




3. Install the upper oil pan to the engine block (1).

4. Install the wiring harness clips (3).

5. Install the upper oil pan bolts (2, 4).





Caution: Refer to Fastener Caution Fastener Caution.

6. Tighten the upper oil pan bolts (1, 2) in sequence to 21 Nm (15 lb ft).




7. Install the 2 flywheel housing to upper oil pan bolts (1) and tighten to 50 Nm (37 lb ft).

8. Install the engine flywheel. Refer to Engine Flywheel Replacement Service and Repair.

9. Install the lower oil pan. Refer to Lower Oil Pan Replacement Lower Oil Pan Replacement.

10. If vehicle is a 4WD, install the front differential carrier. Refer to Differential Carrier Assembly Replacement (2500 4WD) .

11. If vehicle is a 2WD, connect the relay rod to the pitman arm and idler arm. Refer to Relay Rod Replacement (Dual Rear Wheels or Crew Cab With SRW) Relay Rod Replacement (Dual Rear Wheels or Crew Cab With SRW)Relay Rod Replacement (SRW Except Crew Cab With SRW) Relay Rod Replacement (SRW Except Crew Cab With SRW).

12. Relearn the crankshaft position reluctor wheel. Refer to Crankshaft Position Reluctor Wheel Learn Testing and Inspection.