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Really excellent write up. On the choice of sealants, Permatex Ultra-Black might be different from other black RTV sealants in that you do not have to wait an hour to re-torque it. (Recall your discussion of sealants and the apparent disadvantage of black RTV). Thanks very much.

Spock
 

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From what I've read here, it sounds like a trip to the muffler shop to have the guys loosen the nuts and apply anti-seize might be a really cost effective endeavour if you value your time and your sanity!

Spock
 

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Instructions to this project are very accurate. In my case on an 04 Vulcan removing the upper intake manifold gave me plenty of room for those two rear exhaust to y-pipe bolts. PB Blaster and a breaker bar loosened everything with no problem. Lifting the vehicle a bit higher will allow the y-pipe to come out easier (I used 2X4's underneath the jacks) no O2 sensors have to be removed either. Slowly bring it down while rotating and lifting (if that makes any sense) Just make sure to place something over the cv boot (I used a mover's blanket) so not to rip it when removing the y-pipe.

Once the y-pipe is out the oil pan is simple, just remember to add the sealant in the two spots and do not over tighten the bolts.

There is one task that always gives me problems and that is keeping the crush ring/gasket in it's place when re-installing the y-pipe (rear exhaust manifold to cat, 2F1Z-5F263-BA) Having removed y-pipe from my vehicle over five times for other reasons, this gasket always falls out when tightening the bolts.
 

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In your original thread, you say:
"- More information can be found here:
http://www.autozone.com/repairinfo/repairInfoLanding.jsp
(that is where your link now takes us)

However, Ford has been here before you and already screwed you royally:
"Unfortunately, at this time we have been requested by Ford Motor Company to remove the Vehicle Repair Guides for all Ford vehicles. We apologize for any inconvenience this may cause. We are working to correct the situation. Thank you for your patience and understanding."

Somehow, I'm not surprised. Do their executives, board of directors and investors really need every single solitary tinie winie ounce of profit that they can squeeze out of us before we bust? Geez Ford!

I have access to other Ford manuals, so I'm not dead in the water. But Ford's actions like this make me not want to have anything further to do with them. That's my marketing opinion of one. :angry:
 

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Excellent instructions. But still have oil pan leak. How to stop leak. 2002 Taurus Duratec.

Believe it is oil pan leak. Before repair, used fluorescent oil dye and found oil mainly passenger side oil pan gasket area. None near front crank seal. Generally oily above oil pan but could not see fluorescent dye above.

Changed gasket and used RTV only at were timing cover joins block.

Used Fel Pro OS30697R

Torque to spec in recommended sequence to 20 ft lbs. Still leaked mainly on passenger side of pan at gasket but less so. Leaked some near transmission-engine area. Slightly over torqued by less than 5 ft lbs all bolts. Less leak near transmission, no change passenger side engine.

Would it be useful to use RTV on top and bottom of entire gasket?

Saw suggetion to use oil pan and gasket from 2004 DOHC. Post #3 in
http://www.taurusclub.com/forum/87-engine-drivetrain/158733-duratec-oil-pan-gasket.html

But from Rock Auto, oil pans have same part number for 2002 and 2004.
But gaskets are different 2002 compared with 2004.
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2002 oil pan
ATP 103393 {#3F1Z6675DA} $87.79
DORMAN 264445 {#3F1Z6675DA} $91.79
SPECTRA PREMIUM/COOLING DEPOT FP74A {Click Info Button for Alternate/OEM Part Numbers}

2002 GASKET
MAHLE ORIGINAL/VICTOR REINZ OS32244 {Click Info Button for Alternate/OEM Part Numbers} Molded Rubber Info
Lower Oil Pan
Choose: $9.73
FEL-PRO OS30697R {Click Info Button for Alternate/OEM Part Numbers} PermaDry® Info

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2004 OIL PAN
ATP 103393 {#3F1Z6675DA} Info $87.79
DORMAN 264445 {#3F1Z6675DA}

2004 GASKET
MAHLE ORIGINAL/VICTOR REINZ OS32275 $16.54
APEX AOP489 Info $21.79
FEL-PRO OS30729R PermaDry®

How stop Duratec oil leak? Thanks
 

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