Oil pan rusted?
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Junior User
Joined: Sep 2004
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Oil pan rusted?
I brought my 2002 excursion to my diesel service shop, for an oil change, and filter changes. I also asked him if he could tell where I had an oil leak because I left a couple of oil spots on my driveway. I got a call a few hours and he told me that my truck was done but he was gonna leave it on the lift so that he could show me the leak (The tone seemed like a doctor about to tell you about a major illness) when I got there he showed me that the leak was due to my oil pan rotting out!!!!!! and an idea of how much work is involved in changing the pan on a 7.3 diesel...!!!!!!!! I dont understand how a pan could rot out like this the truck is a 2002 with 55k on it.... I'm going to have the dealer look at it since the warranty isn't up untill 2/14/07 (due to the 5 years 5/100k warranty). I hope that they will cover it. Has anyone else had this problem and is it under warranty?
Fleet Owner
Joined: Jun 2004
Posts: 25,090
Likes: 1,112
From: Rio Rico, AZ.
Yeah, that part of the design gets a dunce cap award from me. 
Mine rusted out on the bottom, right next to the drain plug.
I patched it with a fuel tank repair kit from NAPA. Basically it's a piece of fiberglass and some quick set epoxy. It was a lot cheaper and easier than pulling the engine just for that.
My oil pan wasn't completely rotted out up the sides like some of you have reported. Only on the very bottom of the pan was it rusty. So for me it was a no-brainer. I sanded and coated the rest of the pan with POR-15 with an annual inspection and re-application schedule to prevent any more problems.
Mine rusted out on the bottom, right next to the drain plug.
I patched it with a fuel tank repair kit from NAPA. Basically it's a piece of fiberglass and some quick set epoxy. It was a lot cheaper and easier than pulling the engine just for that.
My oil pan wasn't completely rotted out up the sides like some of you have reported. Only on the very bottom of the pan was it rusty. So for me it was a no-brainer. I sanded and coated the rest of the pan with POR-15 with an annual inspection and re-application schedule to prevent any more problems.
Freshman User
Joined: Nov 2005
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One of the weakest parts on the truck has to be the oil pan and the rear differential cover because of rusting. Mine started leaking at about 100,000 miles so I called ford and they sell a Hytemp Anti-corrosion metal extender that stops the rust. I lightly sanded the entire pan and brushed this paint like metal extender on and since have added 60,000 miles without a leak. Ford sells it for about $22.00 a can I think the part # is PM 13A, well worth it versus changing the pan. A must have for trucks that are from the north with a lot of salt and snow!
Cross-Country
Joined: Jun 2006
Posts: 57
Likes: 3
From: Texas
There is - (was) a TSB on this. I check mine everytime I change the oil for possible starting of corrosion. May just preventative paint with POR-15 for piece of mind I guess. Not too much salt on our roads..once a year maybe. TSB 05-20-3 Seems bad that an oil pan is a weak point on a truck,(corrosion wise) seeing as how it catches all debris everyday.
New User
Joined: Sep 2006
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Just did my pan,what a pan in the a-- that was.
Sat under truck for 8 hrs sanding all the paint off it.
Scaped the big rust off, then sanded with 40 grid sand paper.
Had to remove oil filter to access, moved trans lines away to
paint pan with rust bullet, 4 coats total.
Kind of a neat look, that silver color, it sure makes the rust easy to spot again,
seems to be holding up good.
Just remember you will have to lay truck up for 48 hrs for rust bullet to cure.
The hardest part is sanding the area that sits above the frame.
Good luck.
Sat under truck for 8 hrs sanding all the paint off it.
Scaped the big rust off, then sanded with 40 grid sand paper.
Had to remove oil filter to access, moved trans lines away to
paint pan with rust bullet, 4 coats total.
Kind of a neat look, that silver color, it sure makes the rust easy to spot again,
seems to be holding up good.
Just remember you will have to lay truck up for 48 hrs for rust bullet to cure.
The hardest part is sanding the area that sits above the frame.
Good luck.
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Senior User
Joined: Feb 2006
Posts: 441
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From: Byron, IL
I just did mine last week it wasnt to bad just acouple of little spots starting so I caught it before it got bad and now I will check it annually Thanks to this site
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Elder User
Joined: Nov 2005
Posts: 796
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From: North Idaho
I used Rust bullet, http://rustbullet.com/HowItWorks.htm, and have been very pleased by the results. I liked how it went on with minimal surface prep. It has been on for 6 months now and still looking like the day I painted it on. They use a lot of mag chloride on the highway here and is very corrosve, so after the winter is over I should have more info on how it holds up. So far , so good. Here is the kit I used for my oil pan,http://www.rustbullet.com/ProductCar...&idproduct=415
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Junior User
Joined: Sep 2004
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My first thought was to patch it and trade it in, but I love this truck. So I went to the dealer to see what my options were, they couldn't tell me if it would be covered yet, it goes in on tues. my warranty isn't up till Feb. Got my fingers crossed....and yes I do live in the northeast.
Thanks....I will let you know what happends
Thanks....I will let you know what happends
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Junior User
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ok, I brought my truck in and they said that it would not be covered, so I complained and was told that I needed to speak with a manager who was on vacation...!!!!!!! I called her a week later and after a long conversation she told me that she could get it covered, my warranty expires 2/14/07 so she put the order in for the pan... This just saved me $2000 needless to say I'm very happy.
I didn't want to push to issue any further at this time but when the truck goes in I'm going to ask to have the pan coated so it doesn't happen again in a few years. I really do love my truck/SUV.....
I didn't want to push to issue any further at this time but when the truck goes in I'm going to ask to have the pan coated so it doesn't happen again in a few years. I really do love my truck/SUV.....
Snowboard season cometh..
Joined: Jan 2006
Posts: 5,406
Likes: 1
From: Gulf Coast of Florida
You might think about asking to get the new pan from them and have it sandblasted and then powdercoated before they do the swap. That should eliminate any chance of having to deal with this again for you.
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exdriver
1999 - 2003 7.3L Power Stroke Diesel
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Feb 2, 2007 06:53 PM
