In the fall, a small oil leak started on the expo. About a dime size spot in a week. I don't like oil leaks, so even that was bugging me. I was hopeful that it was just something with the filter. Changed the oil, leak didn't go away, just got progressively worse.

Researched issue, decided it must be the oil filter adapter gasket. That just didn't sound fun. Looked under the truck, read what people had paid shops and dealers to cure and decided that it really wasn't going to be any better than it sounded.

Fast forward (or 4 months of procrastination and speedy dry later) and I finally order the gasket from Rock Auto. These guys were great, I didn't ask and they didn't charge more, but they did have FEDEX deliver on Saturday.

After reading more posts of adventures in changing the gasket, I took an alternative approach. My truck is a 4x4, so the differential inhibits access from below. Rather than pull the power steering pump and trying to do the whole operation blind, I dropped the front axle. See below.

Here's the gasket. Note the large hole, that's for the coolant line that runs through the same adapter. As I am also an engineer I will refrain from printing the choice words I had for the guy that designed this junction.

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After getting things apart, the difference between the original and new gaskets can be seen. Notice how flat the o-ring glands on the original (gray) gasket are compared to the new (blue) gasket.

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Here's the work area with the axle assembly removed. This made it much nicer to work.

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While the axle was out and I was cleaning parts anyway, Itook the opportunity to clean up the housing and factory oil drip tray too.

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Here things are getting back together
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There was an odd undercoating type paint on the crossmember. It did not react well with oil and dirt over time. So scraping the gunk off, removed the paint too. So it got some shiny new paint.

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And finally, the half shaft bolts were marked after being torqued, to ensure none were missed.

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In the end, I had to remove and reinstall more pieces with this approach. I think it was worth it,to be able to have good access to the parts and the gasket surfaces for cleaning. I don't think this method really took any more time than it would have taken to struggle with the repair from above.





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Let us know how it works out, I think I have a leak from the same area.

Nice write-up

 

I've put about 100 miles on it with no indication of further issues.

One thing I forgot to mention. Mine has the AWD/4x4 (no 2-high) transfer case, so my front axle has a vent line only, not vacuum lines to disconnect. Ford service manual speaks of vacuum lines.