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My oilpan is leaking I think near the balancer, I have put a new seal and race in on the crankshaft so, I feel pretty confident that it is the pan, it drips weather it is running or not, I would like to buy a replacement anyway. My concern is getting the pan out, looks like an SOB,
#1 is it possible without pulling the trans/engine/frontclip/ ect.. I was thinking of trying to work it in when I got a SFA conversion, but those are not just popping up for sale.
#2 has anyone pulled the crossmember out but cutting the rivets and replaced them with grade 12 bolts, I figured if I took that out, it would obviously drop right out.. again that was why I was considering it with a SFA swap..
Removing that cross member would be nearly impossible, and the engine sits on it anyway. Pulling the pan is a big job. You can get it out if you raise the engine/transmission until it contacts the body, but you have to unbolt the oil pump and pick-up tube and drop them inside the pan, and rotate the crank until you can maneuver the pan past the crank counterweights.
Note that in order to lift the engine enough to do this you need to disconnect the exhaust pipes, fuel lines, transmission oil cooler lines (if AT) alternator and fuel heater wiring, power steering return line, radiator hoses, and engine fan (so it won't hit the radiator) or pull the radiator. Once lifted, it is a good idea to block the engine up since you will be working in between the lifted engine and the frame
Sorry to say, there's no easy shortcut that I know of. Pulling the pan with the engine in the truck is just about as much work as pulling the front clip and lifting out the entire engine/transmission unit where you can get to it.
Is it common on diesels that the engine has to come out to remove the oil pan? I've heard that's the case on newer Fords, but I didn't know it was the case on IDIs.
Is it just not something Ford thought would ever need repair?
Was thinking about this some more, I'm not sure if you will be able to do the pan removal with engine in truck technique after all because of the turbo kit. That sidewinder downpipe is practically contacting the cab already without lifting the engine!
In your case I would examine how much room you have there for upward lift, you may still be able to hoist the driver side up enough to get the pan out on that side. I would definitely plan on "worst case scenario" you might have to go ahead and pull the engine/transmission.