How to Replace the Oil Pan on a Jeep Wrangler JK

Chris

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The engine oil pan keeps the oil in place as the oil pump circulates the oil throughout the engine. The oil pan surrounds the oil pump pickup tube and covers the crankshaft, making its placement and structural integrity important. Because oil temperatures reach high levels and the oil is splashed around at high velocities, leaks are easily developed. A properly installed gasket is the key to having a leak-free oil pan.

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Materials Needed
  • Floor jack
  • Jack stands (x2)
  • 3/8" or 1/2" socket set (10mm-19mm)
  • 3/8" or 1/2" extension (3" and 6")
  • 3/8" or 1/2" ratchet
  • Gasket scraper
  • Oil filter wrench
  • Ft/lb torque wrench
  • In/lb torque wrench (or well-calibrated elbow)
  • Rubber gloves
  • Safety glasses
  • Brake cleaner
  • Rags
  • Engine oil
  • Drain pan
  • Oil pan gasket
  • RTV sealant
Step 1 – Raise and support front end
Remove the engine oil cap. Engage your parking brake. Place your floor jack below one of the front jacking points and raise it until you can fit a jack stand beside it. Lower your Jeep's weight onto the jack stand and repeat the process for the other side.

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Figure 1. Jack up on the frame and put stands under the axle.

Step 2 – Drain engine oil
Position your drain pan beneath the drain bolt at the rear of the oil pan. Remove the drain bolt, noting any copper or metal washers on the drain bolt or oil pan. You'll want to replace it if present. Now remove the oil filter. It's located at the front of the oil pan near the harmonic balancer. You may need an oil filter wrench.

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Figure 2. The oil drain bolt.


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Figure 3. The oil filter.

Step 3 – Remove transmission dust cover
Remove all seven bolts from the transmission dust cover. Once removed, lower the cover off the engine/transmission.

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Figure 4. The transmission dust cover.

Step 4 – Begin removing oil pan
The Jeep JK uses a two piece oil pan. Start by removing the two nuts at the front of the upper oil pan with a 10mm socket.

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Figure 5. The two upper oil pan nut locations.

Step 5 – Remove oil pan
Remove the remaining sixteen bolts from the upper oil pan. An electric or air powered ratchet will greatly speed up this process.

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Figure 6. You can see the upper oil pan bolt locations.

Step 6 – Clean engine and oil pan mating surfaces
Use a gasket scraper to remove the old gasket and RTV material from both surfaces. Afterwards, soak a rag in brake cleaner and rub the surfaces down to achieve a clean surface. Be careful when using the gasket scraper. You don't want to scratch the mating surfaces.

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Figure 7. Removing the old gasket material.

Step 7 – Begin installing the new oil pan
Place four beads of RTV sealant on the spots indicated in Figure 8. These are where the engine block meets with another metal component, such as the timing cover. Without the sealant, oil is otherwise prone to leak through the mating area. The RTV helps hold the oil pan gasket in place while tightening, as well.

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Figure 8. Two of the four places RTV sealer is used.

Step 8 – Bolt the oil pan to the engine
Place the oil pan gasket onto the oil pan and hold the pan against the engine. Start the oil pan bolts by hand, rotating from corner to corner. This will help keep the oil pan lined up with the bolt holes. Remember to install the two nuts at the front of the pan. Tighten the bolts/nuts to 105 in/lb or 9 ft/lbs.

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Figure 9. The installed oil pan.

Step 9 – Install the transmission dust cover
The dust cover bolts to both the engine and transmission. It must be tightened using a multiple step sequence. Start by hand-tightening all seven bolts. Torque the cover to transmission bolts to 25 in/lbs or 2 ft/lbs. Move to the cover to oil pan bolts and torque them to 40 ft/lbs. Do the same for the cover to transmission bolts.

Finish the installation by installing your new oil filter and filling your engines oil to capacity.