Oil Pan: Service and Repair

REMOVAL
1. Remove the engine.
2. Mount the engine on an engine stand with the engine upright. Remove the oil pan and crankshaft oil windage baffle.

CAUTION: Mounting the engine upside down on the engine stand before removing the oil pan may cause sludge to drop into the cylinders and onto the camshaft and valve tappets causing rapid wear when the engine is restarted.

3. Rotate the engine upside down and remove the oil pump and rear main bearing cap.
4. Remove and discard the crankshaft rear main seal.

INSTALLATION

CAUTION: Prevent engine assembly contamination. Always use necessary precautions to prevent old sealer or gasket material from falling into the engine.

1. Thoroughly clean all the oil and the old sealer from the oil pan taking special care to remove all the old sealer from the oil pan gasket groove in the oil pan. Thoroughly clean the oil pan.

NOTE: Thoroughly clean all exposed areas with metal surface cleaner F4AZ-19A536-RA or denatured alcohol. Place special attention on removing the remains of the integral rubber wedge seal. The tabs on the wedge seal tear away from the oil pan gasket when the oil pan is removed and remain lodged between the block and the rear main bearing cap.

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 area at the rear main bearing cap.
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 meeting Ford specification 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").

Cylinder Block Sealer Application:

7. Apply a bead of Ford Gasket Eliminator E1FZ-19562-A or Loctite 515, or equivalent sealer meeting Ford specification ESE-M4G234-A1, to the cylinder block along the corners of the rear main bearing cap joint area, and on the joint face approximately 13 mm (1/2 inch) from the rear of the cylinder block.
8. Verify that the lower rear main bearing insert is in place and install the rear main bearing cap and snug the bolts.

NOTE: New main bearing cap bolts must be used during assembly.

Rear Main Bearing Cap View:

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 ensure the crankshaft rear oil seal will seat properly when installed in the bore.

NOTE: The rear main bearing cap must be aligned and installed properly to seal. Misalignment will cause an oil leak,

10. Tighten the bolts evenly to 90-104 Nm (66 77 ft lb).

Engine Oil Pan Installation:

11. Fill the cavities on both sides of the rear main cap with Gasket Eliminator E1FZ-19562-A or Loctite 515 or equivalent sealer meeting Ford specification ESE-M4G234-A1.

CAUTION: Use a new oil seal. Failure to install a new seal, or incorrect installation will result in an oil leak after the vehicle is returned to service.

12. 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).
13. Install the windage tray and tighten to 17-21 N-rn (13-15 ft lb).
14. Place a bead of Ford Silicone Sealer F1AZ-19562-A, Loctite 598 or equivalent sealer in the oil pan gasket flange at the radius areas at the front and rear of the oil pan.

Oil Pan Installation:

15. Place the oil pan gasket in place on the flange of cylinder block while setting integral wedge seal in place.
16. Place a bead of Ford Silicone Sealer F1AZ-19562-A, or Loctite 598 or equivalent sealer meeting Ford specification WSE-M4G279, on top of the oil pan gasket at the radius areas at the front and rear of the oil pan.
17. Place a bead of Ford Silicone Sealer F1AZ-19562-A or Loctite 598 sealer or equivalent meeting Ford specification WSE-M4G277, on the cylinder block at the cylinder block-to-front cover joint area.
18. Set the oil pan in place as the wedge seal is placed in position. Install and snug four oil pan nuts tight enough to align the bolt holes, but loose enough that the oil pan may be pushed backwards.
19. 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 oil pan spacer should be used.

20. Install the remaining oil pan bolts and finger-tighten.
21. Tighten the oil pan nuts and bolts evenly to 7-10 Nm (5-7 ft lb).

NOTE: Do not put oil in the engine or run the engine until the next day to allow the sealers to set up properly. If time is not allowed for sealers to cure, engine will leak.

22. Always use a new crankshaft rear oil seal.
23. Determine if oil pan spacers will be required at installation.

CAUTION: Failure to measure the required spacer thickness will result in insufficient or excessive clearance between the oil pan and the transmission when installed in the vehicle. This can result in oil pan damage and an oil leak.

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 cylinder block. Refer to the following procedure for checking this dimension.

Rear View Of Engine:

a. With the oil pan installed on the engine, position straightedge DB3L-42O1-A or equivalent flat on the rear of the cylinder block so that it extends over one of the oil pan/transmission bolt mounting pads.

Spacer Selection Chart:

b. Using Feeler Gauge D81L-4201-A or equivalent, measure the gap between the mounting pad and the straightedge. Repeat the procedure for the other mounting pad. Select oil pan spacer of the required thickness from the chart.
C. Install the selected oil pan spacer to the mounting pads on the rear of the oil pan before bolting the engine and transmission together.
24. Remove engine from stand and install engine into vehicle.