Gear Housing

GEAR HOUSING

REMOVAL
1. Disconnect the battery negative cables.
2. Raise vehicle on hoist.
3. Partially drain engine coolant into container suitable for re-use.
4. Lower vehicle.
5. Remove radiator upper hose.
6. Disconnect coolant recovery bottle hose from radiator filler neck and lift bottle off of fan shroud.
7. Disconnect windshield washer pump supply hose and electrical connections and lift washer bottle off of fan shroud.
8. Remove lower fan shroud fasteners. Disconnect fan drive wire harness.
9. Remove the upper fan shroud-to-radiator mounting bolts.
10. Remove viscous fan/drive assembly.
11. Remove the accessory drive belt.
12. Remove the cooling fan support/hub from the front of the engine.
13. Raise the vehicle on hoist.
14. Remove the crankshaft damper and speed indicator ring.
15. Lower the vehicle.
16. Remove the hydraulic pump.
17. Remove the accessory drive belt tensioner.
18. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces.
19. Remove the fuel injection pump.
20. Disconnect the camshaft position sensor connector.
21. Disconnect and remove engine speed sensor.
22. Remove the camshaft.
23. Remove the six front oil pan fasteners.
24. Remove the gear housing fasteners.

NOTE: Use care when removing the gear housing, to avoid damage to the oil pan gasket, as the gasket will be reused if it is not damaged.

25. Slide a feeler gauge between the gear housing and oil pan gasket, to break the gasket seal.
26. Remove the gear housing and gasket.
27. Clean the gasket material from the cylinder block and gear housing.

INSTALLATION
1. Inspect oil pan gasket. If torn, gasket must be replaced.
2. Install a new gasket and the gear housing. Torque bolts to 24 Nm (18 ft. lbs.). Follow torque sequence.
3. If a new housing is installed, the camshaft position sensor, and engine speed sensor must be transferred to the new housing.
4. Connect the camshaft position sensor connector.
5. Install and connect engine speed sensor.
6. Install the injection pump.
7. Install the camshaft. Align the crankshaft and camshaft gear marks as shown in.
8. Install a new front crankshaft seal into the gear cover.
9. Apply a bead of Mopar Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover. Be sure to surround all through holes.
10. Using the seal pilot to align the cover, install the cover to the housing and install the bolts. Tighten the bolts to 24 Nm (18 ft. lbs.) torque.
11. Remove the seal pilot. Install front seal dust shield.
12. Raise the vehicle.
13. Trim any excess gear housing gasket to make it flush with the oil pan rail.
14. Install the crankshaft damper and speed indicator ring. Torque bolts to 40 Nm (30 ft. lbs.), plus an additional 60°.
15. Lower vehicle.
16. Install the fan support/hub assembly and tighten bolts to 32 Nm (24 ft. lbs.) torque.
17. Install the hydraulic pump.
18. Install the accessory drive belt tensioner. Torque bolt to 43 Nm (32 ft. lbs.) torque.
19. Install the accessory drive belt.
20. Install the upper cooling fan and shroud together.
21. Install lower shroud and connect fan drive harness connector.
22. Install the windshield washer reservoir to the fan shroud and connect the washer pump supply hose and electrical connection.
23. Install the coolant recovery bottle to the fan shroud and connect the hose to the radiator filler neck.
24. Install the radiator upper hose and clamps.
25. Add engine oil.
26. Add coolant.
27. Connect the battery cables.
28. Start engine and inspect for leaks.