Replacement procedures for your oil pan seal are below. These instructions are for the 3.8L engines. Please specify if you have a different size engine.
NOTE: It is a good idea to place the vehicle's ignition keys in the box with the new oil containers so that you do not accidentally start the vehicle without first filling the engine with oil.
Disconnect the negative battery cable.
Remove the air inlet tube from the throttle body and air cleaner housing.
Remove the upper radiator plastic cover and the hood weather seal.
Remove the windshield wiper arms.
Remove the left-hand cowl vent screen and the windshield wiper module.
Install an engine support tool, such as the Ford Three Bar Engine Support D88L-6000-A. Do not support the weight of the engine yet.
Apply the parking brake and block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
Remove the front engine mount through-bolts.
Using the engine support tool, raise the engine slightly.
Remove the starter motor.
If equipped, remove the automatic transmission cooler lines.
Drain the engine oil and remove the engine oil filter.
Remove the oil pan-to-bell housing bolts and the bolts at the crankshaft position sensor lower shield.
Remove the remaining oil pan mounting bolts.
Separate the steering column shaft at the pinch bolt joint.
Position a transmission jack under the front sub-frame, then support the front sub-frame with the jack.
Matchmark the sub-frame position in relation to the vehicle chassis for reinstallation purposes.
Remove the six rear and the two front mounting bolts from the front sub-frame.
Remove the lower shock absorber-to-lower control arm bolts and nuts on both sides of the vehicle.
Cautiously lower the front sub-frame.
Remove the oil pan. Pour any residual oil out of the oil pan.
If necessary, remove the oil pump screen and tube retainer bolts, and support bracket nut. Remove the oil pump screen cover and tube. Discard the old oil pump inlet tube gasket.
((Be sure to tighten the oil pan mounting bolts in the sequence shown to ensure proper sealing))
Install the oil pump screen cover and tube, along with a new gasket. Tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm) and the bracket nut to 30-40 ft. lbs. (40-55 Nm).
Trial fit the oil pan on the engine block to ensure that there is adequate clearance to prevent the new sealer from being scraped off of the engine block by the oil pan.
Clean the mating surfaces of the oil pan and engine block of all old sealant and oil residue with Ford Metal Surface Cleaner F4AZ-19A536-RA or equivalent.
It is imperative to use the proper solvent when cleaning the engine block-to-oil pan surfaces, otherwise the new sealer may not adhere properly. Also, when using silicone sealer, assembly must be performed within 15 minutes of applying the sealer, otherwise the sealer will start to set-up and lose its sealing effectiveness.
Apply a bead of silicone sealer, such as Ford Silicone Gasket and Sealant F6AZ-19652-AA, to the oil pan.
Install the oil pan, then install all of the oil pan mounting bolts. Tighten the bolts, in the sequence shown in the accompanying illustration, to 80-106 inch lbs. (9-12 Nm).
Raise the front sub-frame into position, then install the lower shock absorber mounting bolts and nuts to 103-143 ft. lbs. (140-195 Nm).
Install the two front and six rear sub-frame bolts loosely.
Adjust the position of the front sub-frame assembly until the matchmarks are correctly aligned. Then, tighten the large sub-frame bolts to 83-113 ft. lbs. (113-153 Nm) and the small bolts to 72-97 ft. lbs. (98-132 Nm).
It is important that the front sub-frame be realigned as when removed to ensure proper chassis geometry.
Connect the steering column shaft at the pinch bolt joint. Tighten the pinch bolt to 30-42 ft. lbs. (41-57 Nm).
Install the starter motor and the automatic transmission cooler lines, when applicable.
Install the engine oil drain plug and a new oil filter.
When seating the engine on the mounts, set it on the left-hand side mount first.
Slowly lower the engine until it is resting on the front engine mounts, then install the mount through-bolts. Tighten them to 35-50 ft. lbs. (47-68 Nm).
Lower the vehicle and remove the rear wheel blocks.
Remove the engine support tool.
Install the wiper module and left-hand cowl vent screen.
Install the windshield wiper arms and the hood weather seal.
Install the radiator upper plastic cover and the air inlet tube.
It is vitally important to fill the engine with oil prior to starting it, otherwise severe engine damage will occur.
Fill the engine with the proper type and amount of clean engine oil.
Connect the negative battery cable, then start the engine and check for oil leaks.
After 3-5 minutes, stop the engine and check the oil level; add more oil if necessary.
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Tuesday, January 27th, 2009 AT 1:09 AM