93 Aero 4.0L front oil pan leak......
 

Well I've got an nice steady leak coming from the front of the pan.... running aft of course (downhill, windflow). She's down right now for an AC overhaul and new PS pump/hoses, but I'm inspecting to see what is next to get this stinking oil leakage stopped.

Front HB removal and seal of course, done in situ (in position). But if it is actually the oil pan/seal, can that be done there also? Front of the pan looks tight to the crossmember, and with no idea of how the internals look (tray baffles, pump pickup) I've no clue if it will come off. Once she is back up and running I'll ascertain where this leak originates.

Interweb searches show the 90-94 4.0L engine is notorious for pan gasket leaks. None of the writeups I've found thus far determine if that pan can be pulled where she sits.

Anyone done this leak repair in position? Thanks folks, appreciated.

I've done it on both my vans; a 2wd and a 4wd. I had to remove the engine mount nuts and lift the engine up enough for the oil pan to clear cross member. There is a baffle, and the pickup that you have to clear:

https://picasaweb.google.com/1155523...65409052994466

I also removed the transmission:

https://picasaweb.google.com/1155523...64924678327682

which in my case also meant removing the transfer case:

https://picasaweb.google.com/1155523...64921320735890

Nice photo log and even better with all the notations. Very nice work!

I suspected the oil pan would not button hook around the X member, without some trickery. Are you saying that the trans MUST be removed and asided to do the oil pan? What I suspected, but was hoping it wouldn't be. I'm still hopeful in my case that the front crank seal is the culprit and all I have to do is pull the HB and install a front seal..... we shall see.

Forget to mention that I had a mechanic replace the pan gasket about 1.5 years back, when I had a pair of new heads installed. My rear intake gasket was bad, pouring oil out to what looked to be a rear crank seal. Basically all gaskets on the short block, new heads, all new gaskets up top. And now this :-arrgh

Thank you!

I don't think it's possible to drop the pan without dropping the transmission, or the front crossmember, which would be much more involved.

First, you need to jock the engine around in order to position it so the oil pan clears the crossmember. Then you drop the pan, and have to slide it out from the back, which is not possible if the transmission is still attached.

If the oil pan gasket was properly replaced 1.5 years ago, it should still be good. If you try to replace the front crank seal and gasket of the front cover, you will disturb the oil pan gasket, possibly damaging it.

Thank you for sharing your experience...... I hoped when the last mechanic did my pseudo overhaul, that my leak problems would be over. Once I get this AC repaired and PS pump/hoses installed and running (mid 90s here, AC would be wonderful) I'll study the bottom of the pan closely to see if I can zero in on the source of the oil.