Remove the engine assembly from the vehicle.
Mount the engine on a suitable engine stand with the oil pan facing up.
Remove the oil pan retaining bolts and remove the oil pan.
Remove the oil pan gasket, oil pump, oil baffle, rear main bearing cap and wedge seal.
Remove and discard the crankshaft rear main seal.
Thoroughly clean the gasket mating surfaces of the engine block, oil pan and the rear main bearing cap.
Clean the oil seal recess in the cylinder block and main bearing cap. Inspect and clean the oil seal contact surface on the crankshaft.
Oil Pan Installation View
NOTE : Ford Gasket Eliminator, E1FZ-19562-A is equivalent to Loctite(R) 515. Ford Silicone Sealer, F1AZ-19562-A is equivalent to Loctite(R) 598.
Clean the gasket surfaces of the oil pan. Thoroughly clean all oil and all residual old 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.
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.
Thoroughly clean all oil and old sealer from the cylinder block oil pan sealing area and the rear main bearing cap joint area.
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.
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.
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").
Place a bead of Loctite(R) 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
Coat the main bearing insert and crankshaft journal with SAE 50 Service SG (ESE-M2C39-F) oil, apply Loctite(R) 515 sealer to the rear main bearing cap as shown in the illustration. Verify the main bearing insert is properly installed.
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.
NOTE : The rear main bearing cap MUST be aligned and installed properly to seal. Misalignment will cause an oil leak.
New rear main bearing cap bolts must be used. Tighten the bolts evenly to 90-104 Nm (66-77 ft lb).
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.
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 Loctite(R) 515 sealer.
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.
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 screws to 17-21 Nm (13-15 ft lb).
Install the oil baffle assembly and tighten the nuts to 17-21 Nm (13-15 ft lb).
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 steps a, b, c, and d below for checking this dimension.
CAUTION: Failure to measure the required spacer thickness will 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.
Rear View Of Engine
With the oil pan installed on the engine, position straightedge D83L-4201-A or equivalent flat on the rear of the engine block (as shown) so that it extends over one of the oil pan/transmission bolt mounting pads.
Oil Pan To Transmission Spacer Usage Chart
Using feeler gauge D81L-4201-A or equivalent, measure the gap between the mounting pad and the straight edge. Repeat the procedure for the other mounting pad. Select spacers of the required thickness from the chart.
Install the selected spacers to the mounting pads on the rear of the oil pan before bolting the engine and transmission together.
Remove the oil pan and position the correct spacers for pan installation.
Place a bead of Loctite(R) 598 sealer in the oil pan gasket groove at the radius areas at the front and rear of the oil pan.
Place the oil pan gasket into the groove in the oil pan.
Place a bead of Loctite(R) 598 sealer on top of the oil pan gasket at the radius areas at the front and rear of the oil pan.
Set the oil pan in place and finger-tighten the oil pan nuts on the studs enough to align the bolt holes, but loose enough to allow the pan to move.
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.
Install the remaining oil pan bolts and finger-tighten.
Tighten the oil pan nuts and bolts evenly to 7-10 Nm (62-88 in lb).
Rear Main Seal Installation Tool
Always use a new rear oil seal. Coat the rear main seal-to-cylinder block surface of the oil seal with oil X0-5W30-QSP (WSE-M2903-A1) or equivalent SAE 5W-30 Service SG oil. Coat the seal contact surface of the oil seal and crankshaft with heavy SF engine oil. Install the new seal using Rear Oil Seal Installer T95T-6701-A.
Remove the engine from the stand and reinstall in the vehicle.
NOTE : It is recommended that the engine not be run or oil be added for 24 hours to allow sealers to cure properly.