Oil Pan: Installation

All vehicles

1.

Apply a 5.5 mm (0.21 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the 2 engine front cover-to-cylinder block joint areas on the sealing surface of the oil pan.

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NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.

NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

2.
Apply a 3 mm (0.11 in) bead of Motorcraft ® High Performance Engine RTV Silicone on the inside edge of the oil pan to the sealing surface of the oil pan-to-engine block mating surface.

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3.

Apply a 5.5 mm (0.21 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.

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NOTE: Keep the oil pan as close as possible to the transmission while installing, then slide forward towards the engine front cover to prevent wiping off of the sealant.

NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application.

4.
Install the bolts finger tight.

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5.

Install the LH bell housing-to-oil pan bolts.

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6.

Install the RH bell housing-to-oil pan bolt.

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7.

Tighten the pan bolts in sequence.

Fig 1: Oil Pan Bolts Tightening Sequence

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8.

Install the 4 lower engine front cover bolts.
- Tighten finger-tight.

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9.

Install the remaining oil pan bolts. Tighten in 3 stages in the sequence shown.
- Stage 1: Tighten bolts 1-9 and 11-14 to 20 Nm (177 lb-in), then rotate an additional 45 degrees.
- Stage 1: Tighten bolts 15 and 16 to 10 Nm (89 lb-in), then rotate an additional 45 degrees.
- Stage 1: Tighten bolt 10 to 20 Nm (177 lb-in), then rotate an additional 90 degrees.

Fig 2: Oil Pan Bolts Tightening Sequence

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10.

Tighten the 4 lower engine front cover bolts.
- Tighten to 48 Nm (35 lb-ft).

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11.

Tighten the LH bell housing-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).

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12.

Tighten the LH bell housing-to-oil pan bolts.
- Tighten to 48 Nm (35 lb-ft).

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13.

Tighten the engine-to-bell housing bolt above the starter motor and the bell housing-to-oil pan bolt below the starter motor.
- Tighten to 48 Nm (35 lb-ft).

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14.

Tighten the 2 transmission crossmember nuts.
- Tighten to 103 Nm (75 lb-ft).

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15.

Attach the generator wiring harness retainer to the engine block.

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Four Wheel Drive (4X4) vehicles

NOTE: Use care when positioning the front axle housing, or the vacuum lines to the axle solenoid may become disconnected or damaged.

16.
Raise the front axle carrier into position.

17.

Install the lower front axle carrier mounting bushing bolt.
- Tighten to 150 Nm (111 lb-ft).

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18.

Install the axle shaft housing carrier bushing bolt.
- Tighten to 150 Nm (111 lb-ft).

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19.

Install the upper front axle carrier bushing bolt.
- Tighten to 150 Nm (111 lb-ft).

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All vehicles

20.

Position the crossmember and install the nuts and bolts.
- Tighten to 90 Nm (66 lb-ft).

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21.

Attach the generator wiring harness to the engine front cover.

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22.

Install the transmission cooler line bracket and nut to the engine front cover stud bolt.
- Tighten to 12 Nm (106 lb-in).

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23.

Attach the starter motor wiring harness retainer to the oil pan.

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24.

Install the starter motor. Refer to: Starting System .

NOTE: Do not lubricate the engine oil filter gasket.

25.
Install a new engine oil filter.
- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.

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26.

Tighten the 4 upper bell housing-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).

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27.

Install the selector lever cable bracket and selector lever cable bracket bolts.
- Tighten to 48 Nm (35 lb-ft).

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28.

Connect the 2 CMS electrical connectors and retainers.
- Connect the transfer case electrical connector harness retainer.
- Connect the transmission harness electrical connector and harness retainers.

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29.

Connect the transfer case electrical connector.

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30.

Install the fuel lines in the retainer on the rear of the transmission.

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31.

Install the fuel lines in the bracket on the upper bell housing.

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32.

Install the skid plate and the 4 bolts.
- Tighten to 40 Nm (30 lb-ft).

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33.

If equipped, install the lower air deflector and the 8 pushpins. Turn the 4 quarter-turn retainers.

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34.

If equipped, install the splash shield and the 4 fasteners.

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35.

Install the oil level indicator.

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36.

Fill the engine with clean engine oil.

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37.

Connect the battery ground cable. Refer to: Battery, Mounting and Cables .

38.

Adjust the selector lever cable and install the selector lever cable end on the manual control lever. Verify the selector lever cable is correctly adjusted. Refer to: Automatic Transaxle Transmission External Controls .