Dorman 635-518 Engine Rear Main Seal Cover Removal and Installation Instructions

ATTENTION

Refer to the appropriate shop manual for your vehicle to obtain specific service procedures for this part. If you do not have a service manual or lack the skill to install this part, it is recommended that you seek the services of a qualified technician. Pay special attention to all cautions and warnings included in the shop manual. Read and follow all instructions carefully. This product is only designed to function properly on specific vehicle applications. Please verify that the vehicle requirements match the product specifications and application notes for this part.

Product Information

Part Number: 635-518

Compatible Vehicles:

• General Motors: 1997–2017
• Isuzu: 2003–2016
• Saab: 2005–2009
• Workhorse: 2004–2012

GENERAL TECH TIPS

• Do not reuse the crankshaft oil seal or rear cover gasket.
• Do not apply any type of sealant to the rear cover gasket, unless specified.
• A special tool is used in this procedure to properly center the crankshaft rear oil seal.
• All gasket surfaces should be free of oil or other foreign material during assembly.
• The crankshaft rear oil seal MUST be centered in relation to the crankshaft.
• An improperly aligned rear cover may cause premature rear oil seal wear and/or engine assembly oil leaks.

Safety Reminder

PLEASE WEAR SAFETY GLASSES! ?

Removal Instructions

STEP 1: Remove the automatic transmission flexplate.

Illustration depicts the rear of an engine. An orange arrow points to the area where oil pan-to-rear oil seal housing bolts are located.

STEP 2: Remove the oil pan-to-rear oil seal housing bolts.

Illustration shows the rear of an engine with several bolts. Orange arrows indicate the removal of these bolts, numbered 2, 3, and 4, corresponding to the rear oil seal housing and its gasket.

STEP 3: Remove the rear oil seal housing bolts.

Illustration shows the rear of an engine with several bolts. Orange arrows indicate the removal of these bolts, numbered 2, 3, and 4, corresponding to the rear oil seal housing and its gasket.

STEP 4: Remove the rear oil seal housing (2) and gasket (3). Discard the gasket.

Illustration shows the rear of an engine with several bolts. Orange arrows indicate the removal of these bolts, numbered 2, 3, and 4, corresponding to the rear oil seal housing and its gasket.

STEP 5: Remove and discard the rear oil seal.

Illustration shows the rear of an engine with several bolts. Orange arrows indicate the removal of these bolts, numbered 2, 3, and 4, corresponding to the rear oil seal housing and its gasket.

Installation Instructions

STEP 1: Apply a 5 mm (0.2 in) bead of sealant, 20 mm (0.8 in) to the 2 joints at the rear of the block/pan.

Illustration shows the rear of an engine. Orange arrows indicate the application of sealant along the joints at the rear of the block/pan.

STEP 2: Inspect the rear oil gallery plug for proper installation.

Close-up illustration of the engine rear, showing the oil gallery plug. A measurement of 0.8-1.4 mm (0.0315-0.055 in) is indicated for proper plug installation. An orange arrow points to the plug.

STEP 3: Install the 635-000 guide cone and bolts onto the rear of the crankshaft.

Illustration shows the rear of the crankshaft. An orange arrow indicates the installation of the 635-000 guide cone and bolts onto the crankshaft.

STEP 4: Install the NEW rear housing gasket (1), rear housing with seal (2), rear housing-to-engine bolts (3) and oil pan-to-rear housing bolts (4).

Illustration shows the rear of the engine. Orange arrows point to the components being installed: the new rear housing gasket (labeled 1), the rear housing with seal (labeled 2), rear housing-to-engine bolts (labeled 3), and oil pan-to-rear housing bolts (labeled 4).

STEP 5: Tighten the rear housing-to-engine bolts until snug. Do not overtighten.

NOTE: Refer to shop manual or specific service procedures for fuel tank fastener safety.

Illustration shows the rear of the engine. Orange arrows indicate the tightening of rear housing-to-engine bolts, with a number 3 pointing to the bolts.

STEP 6: Tighten the oil pan-to-rear housing bolts to 12 N·m (106 lb·in).

Illustration shows the rear of the engine. Orange arrows indicate the tightening of oil pan-to-rear housing bolts.

STEP 7: Tighten the rear housing-to-engine bolts to 30 N·m (22 lb·ft).

Illustration shows the rear of the engine. Orange arrows indicate the tightening of rear housing-to-engine bolts, with a number 3 pointing to the bolts.

STEP 8: Remove the 635-000 guide.

STEP 9: Install the automatic transmission flexplate.

Support

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Please call our Technical Support team for assistance from our team of certified automotive experts.

1-800-523-2492

Disclaimer

Even though every attempt is made to ensure this information is complete and accurate, it is impossible to account for all possible circumstances or situations. Please consult with a qualified auto technician before attempting to perform any work you are not qualified to do. Automobiles can be hazardous to work on; be sure to take all necessary safety precautions. Failure to do so may result in property damage or personal injury. Certain motor vehicle standards and performance requirements may apply to your motor vehicle (such as Federal Motor Vehicle Safety Standards by the National Highway Traffic Safety Administration). Be sure that your work is performed in accordance with such standards and that you do not disable any motor vehicle safety feature.