Oil Pan: Service and Repair
*** THIS ARTICLE REFLECTS CHANGES MADE BY TSB 9518 DATED JANUARY 16, 1995
REMOVAL
1. Position the vehicle on a suitable hoist.
2. Disconnect the negative battery cable.
3. Raise the vehicle and remove the starter motor.
4. Remove transmission, transfer case, transmission crossmember and flywheel.
5. Perform the following steps:
a. Remove the pivot bolts and nuts from both lower control arms, to allow the control arms to hang. Position jack stands under control arms, then remove pivot bolts.
b. Remove the control arm rear pivot cross-member.
c. Remove the front drive axle assembly mounting bolts and allow the axle to hang out of the way.
6. Drain the engine oil and remove the filter.
7. Disconnect the low oil level sensor from the engine oil pan.
8. Remove the engine oil pan retaining bolts and nuts.
9. Remove the oil pan.
10. Remove the baffle assembly and oil pump assembly.
11. Remove the oil pan gasket and the crankshaft rear main bearing cap and wedge seal
INSTALLATION
NOTE: Ford Gasket Eliminator, E1FZ-19562-A is equivalent to Locktite 515, and Ford Silicone Sealer, F1AZ-19562-A is equivalent to Locktite 598.
1. Clean the gasket surfaces of the oil pan. Thoroughly clean all oil and all residual oil sealer from the oil pan. Remove all the old sealer from the oil pan gasket groove in the oil pan sealing surface. Thoroughly wash the oil pan.
2. Thoroughly clean all the old sealer from the rear main bearing cap using a scraper and wire wheel. The original sealer used during production assembly becomes extremely hard after it has cured. It is extremely important that all old sealer is removed from all joining faces and grooves.
3. Thoroughly clean all oil and old sealer from the cylinder block oil pan sealing area and the rear main bearing cap joint area.
4. Thoroughly clean all oil and old sealer from the wedge seal sealing area at the rear main bearing cap and the oil pan gasket groove.
5. After all parts have been thoroughly cleaned and washed, it is necessary and extremely important that they be wiped down with Extra Strength Spot and Stain Remover B7A-19521-AA (ESR-M5B197-A) or Denatured Alcohol.
6. Thoroughly clean the transmission bell-housing area and the rear of the cylinder block. Oil removal should be verified with an ultraviolet lamp ("black light").
7. Place a bead of Locktite 515 sealer along the block corners of the rear main bearing cap joint area, and on the joint face approximately 1/2 inch from the rear of the block.
Rear Main Bearing Cap View:
8. Coat the main bearing insert and crankshaft journal with SAE 50 Service SG (ESE-M2C39-F) oil, apply Locktite 515 sealer to the rear main bearing cap as shown in the illustration. Verify the main bearing insert is properly installed.
9. Align the rear main bearing cap to block by moving the bearing cap fore or aft so the rear seal stop (located approximately 1/2 inch inward in the rear oil seal bore) of the block and cap line up. This will assure the rear main oil seal will seat properly when installed in the bore.
10. New rear main bearing cap bolts must be used. Tighten the bolts evenly to 90-104 Nm (66-77 ft lb).
NOTE: The rear main bearing cap must be aligned and installed properly to seal. Misalignment will cause an oil leak.
11. Use a new wedge seal. Fill the cavities for the wedge seal on both sides of the rear main cap and the small groove in the oil pan gasket area of the rear main cap with Locktite 515 sealer.
CAUTION: Use a new oil seal. Failure to install a new seal, or incorrect seal installation, will result in an oil leak after the vehicle is returned to service.
12. Place wedge seal in position and use a flat blade screwdriver or equivalent to fully seat the wedge seal, forcing the excess sealer out around the seal. Do not remove the excess sealant.
13. Clean and inspect the oil inlet tube. Prime the oil pump by filling the inlet opening with oil while rotating the shaft until oil emerges from the outlet opening. Install the pump and screen and tighten the bolts to 17-21 Nm (13-15 ft lb).
14. Install the oil baffle assembly and tighten the nuts.
15. Determine if shim spacers will be required at installation.
NOTE: The transmission bolts to the engine and oil pan when installed, so it is important to measure the gap between the surface of the rear face of the oil pan (at the spacer locations) and the rear face of the engine block. Refer to the following procedure for checking this dimension.
NOTE: If the same oil pan that was removed is to be installed, the existing spacers may be used. If a new oil pan is being installed, measure the pan-to-transmission gap as detailed in the following steps.
CAUTION: Failure to measure the required spacer thickness can result in insufficient or excessive clearance between the engine oil pan and the transmission when installed in the vehicle. This can result in oil pan damage, and/or an oil leak.
NOTE: If a new oil pan is being installed, determine the correct spacer thicknesses as follows:
a. Position the oil pan on the engine without the spacers and install the retaining nuts on the four locating studs.
b. Measure the gap between the locating pads on the pan and the transmission converter housing using a feeler gauge.
Spacer Selection Chart:
c. Select spacers of the required thickness from the chart.
d. Remove the oil pan and position the correct spacers for pan installation.
16. Place a bead of Locktite 598 sealer in the oil pan gasket groove at the radius areas at the front and rear of the oil pan.
17. Place the oil pan gasket into the groove in the oil pan.
18. Place a bead of Locktite 598 sealer on top of the oil pan gasket at the radius areas at the front and rear of the oil pan and on the cylinder block at the cylinder block-to-front cover joint area.
Oil Pan Installation:
19. Set the oil pan in place and finger-tighten the oil pan nuts on the studs enough to compress the gasket so the transmission bolts will align with the holes in the oil pan, but loose enough to allow the pan to move when the transmission bolts are installed.
20. Align the rear face of the oil pan with the rear face of the cylinder block.
NOTE: If the rear face of the oil pan cannot be aligned within .010 inch of the rear face of the cylinder block, the appropriate shims should be used.
21. Install the remaining oil pan bolts and finger-tighten.
22. Tighten the oil pan nuts and bolts evenly to 7-10 Nm (5-10 ft lb). Tighten the transmission to oil pan bolts to 38-51 Nm (28-38 ft lb).
23. Always use a new rear oil seal.
CAUTION: This installation procedure requires the use of hand tools only. The use of power tools or hammering on the installer can damage the sleeve and seal.
Rear Main Seal Installation Tool:
24. Attach the rear crankshaft adapter to the rear of the crankshaft using the supplied mounting screws.
Rear Main Oil Seal Installation:
25. Apply a few drops of clean engine oil to the inboard side of the seal/sleeve at the area where the seal contacts the sleeve.
26. Apply a very light film of clean engine oil on the inner diameter of the sleeve and outer diameter of seal.
27. Slide the seal/sleeve over the rear crankshaft seal adapter with flange to the rear of the engine.
28. Use the rear crankshaft seal replacer and supplied bolt to push the rear seal into the cylinder block.
NOTE: It is normal for the seal to sit approximately 0.76 mm (0.030 inch) deeper than the sleeve flange. Do not adjust.
29. Remove the rear crankshaft seal adapter.
NOTE: It is recommended that no engine oil be added for 24 hours.
30. Connect the low oil level sensor to the engine oil pan.
31. Install the oil pan drain plug and the engine oil filter.
32. Perform the following steps:
a. Reposition the front drive axle assembly and install the bolts.
b. Install the control arm rear pivot cross- member.
c. Reposition the lower control arms and install the pivot bolts and nuts.
33. Install the starter motor and a new oil filter.
NOTE: It is recommended that no engine oil be added for 24 hours.
34. Lower the vehicle and fill the crankcase with the recommended quantity and quality of engine oil.
35. Connect the negative battery cable.
NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.
36. Start the engine and check for leaks.