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Procedure for oil pan gasket/rear main seal replacement

Front axle removal

1) Remove skid plate
2) Remove skid plate crossmember
3) Mark CV joint and axle flange
4) Separate axle shafts from axle flange
5) Mark propeller shaft and pinion yoke
6) Remove propeller shaft
7) Remove axle vent tube
8) Support differential with floor jack
9) Remove bolts holding axle to engine
10) Lower jack and remove axle from vehicle

Oil pan and main seal removal

1) Remove dipstick
2) Drain oil
3) Remove engine to transmission support brackets
4) Remove transmission inspection cover
5) Remove oil pan and gasket
6) Remove oil pump from main bearing cap
 Have bucket handy to catch oil in pump during removal
7) Remove rear main bearing cap and discard lower seal
8) Loosen two bearing caps forward of the rear main bearing
9) Remove upper seal with removal tool

Notes:
 Remove negative battery cable
 Place cardboard under vehicle to protect cement from dripping oil
 Clean all mating surfaces of old gasket and sealer
 Make pan installation dowels with 1 1/2- 5/16 bolts cut off bolt heads
and make a slot for screw driver removal

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Procedure for oil pan gasket/rear main seal replacement

Rear main seal and oil pan installation

1) Lightly oil new upper seal with engine oil
2) Rotate seal into block with white facing rear of engine
3) Lightly oil new lower seal with engine oil
4) Install seal in lower main bearing cap white facing rear
5) Apply locktite 515 to each side of main bearing cap(don’t allow
locktite to contact rubber seal)
6) Align bearing using slot alignment dowel and cap bolts
7) Install main bearing cap w/cleaned and oiled cap bolts
 alternately tighten bolts to 85ft lbs, starting with the two main bolts
loosened during removal and working toward the rear main cap
 Tighten all main caps to 85 ft lbs working from to rear
8) Install oil pump torque to 30ft lbs
 Prime pump with oil prior to installation
9) Apply black RTV sealant to the bearing to cap block joints
10) Install the dowels (2) at each end of the block
11) Slide gasket over dowels onto block
12) Install oil pan and torque bolts to 215in lbs

Front axle installation

1) Raise axle into position, loosely install the bolts and nut to the
brackets
2) Tighten all bolt finger tight, then to the following
 Axle to engine mount bolts 75ft lbs
 Axle to engine to transmission 40ft lbs
3) Install axle vent tube
4) Align reference marks on propeller shaft and pinion yoke, install
5) Align reference marks on C/V joints and axle flanges, install
6) Install skid plate crossmember support and skid plate
7) Make sure vehicle is level and check differential fluid
 Add fluid if necessary
8) Remove all supports and lower vehicle
9) Replace filter, add oil, start engine and check for leaks.