Oil Pan Gasket

This procedure covers removal and replacement of the oil pan gasket on a 2007 Ram 3500 with the 5.9L Cummins diesel engine, requiring partial front axle lowering to access the oil pan.

Warnings

Tools required

Parts

• Oil pan gasket × 1 — Use OEM Mopar gasket for 5.9L Cummins
• Oil drain plug crush washer × 1 — Use OEM specification
• RTV silicone sealant × 1 — Mopar or equivalent high-temp RTV

Fluids

• 15W-40 diesel oil or 5W-40 synthetic — 12 qt

Preparation

1. Park vehicle on level surface and apply parking brake. Place wheel chocks behind rear wheels.
2. Ensure engine is completely cool to the touch before starting work.
3. Disconnect negative battery cable to prevent accidental starter engagement.
4. Raise front of vehicle and support on jack stands rated for vehicle weight. Front wheels should be off the ground.
5. Remove factory skid plate if equipped to access oil pan and front axle mounting points.
6. Place oil drain pan under engine oil drain plug.

Procedure

1. 1

   Drain engine oil
   Remove the oil drain plug from the oil pan and allow all engine oil to drain completely into the drain pan. This may take 10-15 minutes. Once drained, reinstall the drain plug with a NEW crush washer and torque to the factory specification (verify value against service data, approximately 50 Nm / 37 ft-lbs). Do not reuse the old crush washer.
   Torque spec

   Oil Drain Plug35 Nm (26 lb-ft)
2. 2

   Remove oil filter
   Remove the oil filter cartridge to allow any residual oil in the filter housing to drain. Set filter aside for reinstallation or replacement after gasket work is complete.
   ⚠Expect additional oil spillage when removing the filter. Position drain pan accordingly.
3. 3

   Support front axle assembly
   Position a transmission jack or sturdy adjustable jack stand under the front axle differential housing. Raise the jack just enough to make contact and support the weight of the axle, but do not lift the vehicle. The jack must remain in position throughout the procedure.
   ⚠️Ensure the axle is securely supported before loosening any mounting bolts. The front axle assembly weighs over 400 lbs.
4. 4

   Disconnect axle vent hose
   Locate and disconnect the front axle vent hose from the axle housing. This small rubber hose prevents fluid pressure buildup and must be disconnected to allow axle lowering. Note its routing for reinstallation.
5. 5

   Lower front axle
   Disconnect and remove the front axle mounting/bracket bolts that secure the axle to the frame mounts. You will need to work on both driver and passenger sides. Slowly lower the transmission jack to drop the front axle assembly enough to gain clearance for oil pan removal. This provides just enough clearance to remove the oil pan. Do NOT disconnect brake lines, CV axles, or steering linkage.
   ⚠Lower the axle slowly and watch for any brake line or CV axle binding. Stop immediately if you feel resistance.
6. 6

   Remove oil pan bolts
   Working from underneath the vehicle, remove all oil pan mounting bolts. There are numerous bolts around the perimeter of the pan; verify the exact count and locations against factory documentation before removal. Keep bolts organized as some may be different lengths. Note the location of any brackets or wiring clips attached to the oil pan.
   ℹ️Some oil may still drain when the pan is loosened. Keep the drain pan positioned under the work area.
7. 7

   Separate and remove oil pan
   Carefully use a plastic pry tool or gasket scraper to break the seal between the oil pan and engine block. Work slowly around the perimeter. Once separated, lower the oil pan carefully, tipping the rear of the pan down first to clear the oil pickup tube. Remove the pan from the vehicle.
   ⚠Do not damage the oil pickup tube inside the pan. Bending or denting this tube will cause oil starvation and engine damage.
8. 8

   Remove old gasket material
   Thoroughly clean all old gasket material from both the engine block mating surface and the oil pan flange. Use a razor blade scraper held flat against the surface to avoid gouging the cast iron block or steel pan flange. Clean both surfaces with brake cleaner and allow to dry completely. Inspect both surfaces for any damage, warping, or cracks.
   ⚠The mating surfaces must be completely clean and free of all old gasket material and oil residue. Any debris will cause leaks.
9. 9

   Install new gasket
   Refer to the specific gasket manufacturer's instructions; the 5.9L Cummins uses a molded one-piece oil pan gasket. If required, apply a small dab of RTV only at the front cover-to-block and rear seal housing-to-block junctions as directed. Position the new oil pan gasket onto the oil pan, ensuring all bolt holes align properly. Some gaskets are adhesive-backed; others may require a light coat of RTV to hold them in place during installation.
   ℹ️Follow the gasket manufacturer's instructions regarding RTV application. Some gaskets require RTV only at corners, while others use RTV as the primary sealant.
10. 10

    Install oil pan
    Carefully raise the oil pan into position, ensuring the oil pickup tube passes through the pan opening without contact or interference. Align all bolt holes and start all bolts by hand before tightening any of them. This ensures proper gasket alignment.
    ⚠Verify the oil pickup tube is properly seated and not touching the pan bottom. Incorrect positioning causes oil starvation.
11. 11

    Torque oil pan bolts
    Torque all oil pan bolts to specification in a sequence starting from the center and working outward in a crisscross pattern. Make multiple passes, first torquing to 50% of specification, then to full torque. This ensures even gasket compression and prevents warping.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)
12. 12

    Raise and secure front axle
    Using the transmission jack, raise the front axle back to its original position. Reinstall all axle mounting bolts and torque to factory specification. Reconnect the axle vent hose to the axle housing.
    ℹ️Ensure axle mounts align properly before forcing bolts into place. Misalignment indicates the axle is not at the correct height.
13. 13

    Reinstall oil filter and refill oil
    Install a new oil filter or reinstall the existing filter if still serviceable. Fill the engine with the specified quantity of 15W-40 diesel oil or 5W-40 synthetic oil through the oil fill cap. The 5.9L Cummins requires approximately 12 quarts of oil with filter change; verify exact capacity against factory documentation and confirm on the dipstick. Install the oil fill cap when complete.
    ℹ️The 5.9L Cummins requires 12 quarts of oil with filter change. Verify oil level on dipstick after filling.
14. 14

    Prime oil system and check for leaks
    Reconnect the negative battery cable. Start the engine and allow it to idle. Monitor the oil pressure gauge to confirm normal pressure builds within a few seconds of starting. Let the engine run for 2-3 minutes while inspecting underneath for any oil leaks at the pan gasket. Shut off engine and recheck oil level, adding oil if necessary.
    ⚠️If oil pressure does not register within 10 seconds, immediately shut off the engine and investigate. Running without oil pressure causes catastrophic engine damage.

Reassembly

1. Reinstall factory skid plate if equipped.
2. Lower vehicle to the ground and remove jack stands.
3. Allow vehicle to sit for 1-2 hours, then recheck oil pan area for any signs of seepage.
4. After the first 50-100 miles of driving, recheck oil level and inspect pan gasket area for leaks.

Verification

• Verify oil pressure reads normal (minimum 10 psi at idle when warm, 30+ psi at highway speeds).
• Inspect oil pan gasket area with engine running and warmed up. There should be no oil seepage or drips.
• Confirm oil level is at the full mark on the dipstick with engine off and vehicle on level ground.
• Test drive vehicle and recheck for leaks after engine reaches full operating temperature.
• Verify front axle is properly secured and aligned, with no abnormal steering or handling issues.

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