notes on gen. 3 oil pan gasket replacement
I'm just finishing up replacement of the oil pan gasket on my gen. 3 duratec. Its pretty much the same as the gen. 4 but the y pipe is just slightly different. The differences that I can tell are:
1. You only need 1 gasket at the rear where the y-pipe meets the flex tube. Ford part #5E241
2. There's an oxygen sensor that needs to be removed before the y-pipe will drop. Its the one that is on the engine side of the rear catalytic converter. Its really tucked up in there and the whole y-pipe will hang on it otherwise. I was able to get a 22 mm open-end wrench on it to break it loose but to continue turning, I had to take a box-end wrench and saw a notch in it. I needed the 12 point increments. I also ended up sawing the wrench off short so that I could clear the y-pipe on the other end of the wrench. A bench grinder comes in handy here.
Other non-gen.3 notes:
3. I had to take a propane torch and a hammer to break loose the rear two bolts where y-pipe meets the flex tube. Just heat the whole thing up until its slightly glowing and then beat on the end of the bolt as well as the junction of the y-pipe and the flex tube. Turns much easier after that. I also ended up replacing these bolts and nuts. The ford dealer wanted about $33 with tax for them. For two bolts and two nuts? That's where I walk.
4. I believe that step 18 may be a little backwards. The oil pan gasket bolts should be torqued _before_ torquing the oil pan to transaxle bolts. At least I think this is what the autozone procedure said. I think that if it is done the other way around, its possible that the pressure on the transaxle may keep the oil pan from seating into the gasket properly.