Oil Pan Install Nightmare

[FLGatorgirl]

1990 FJ62, we have had the truck a few months and it has a little bit of a leak in the oil pan. We were able to get the pan and old gasket off pretty easily. We purchased a cork one piece gasket (Beck Arnley because we could get it quickly). We used "The Right Stuff" sealant. The first attempt at install was a bust because the gasket slid too much while we tried to jockey it in place as it did not seem to want to fit. We cleaned everything up and followed instructions on Mud to let the gasket completely set up on the pan with the bolts in to hold it down. We had to use clamps on the arched ends.

We tried to reinstall today (jacking it up this time for more room to work)
and the pan just doesn't seem to want to snug up. It almost acts like it is hanging up on something. If you get one end in, you can't get the other one in. If you can get both ends somewhat in and start fastening it down, it never snugs up to the bottom of the block. There is a gap I can get the tip of my finger in. We are at a loss for what to do. We have scraped all of the sealant off in prep for another go tomorrow, but can't figure out what we are doing wrong. There has been much cussing and bleeding on my husband's part, so any advice would be appreciated. He has changed out oil pans in many different vehicles and says this is the worst. Oh, and I have motor oil in my hair and road rash from the concrete . Help please!

 

[Godwin]

Back off, take a break, and finish next weekend. In prep for next weekend purchase an OEM oil pan gasket. Installing it will still be tricky but it will fit.

 

[micruz60]

Oilpans never do play nice.
Try to get some longer bolts to start attaching at the four corners, then work around, across and slowly, evenly fasten the pan in place. Make sure that the flange is flat and true across and lengthwise...
Pain in the Azz, but you'll get it there.

 

[FLGatorgirl]

Forgot to mention that my husband's only guess on the problem is that the gasket is too stiff and not compressing in the arched areas at the ends. Also, if I understand the FSM correctly, you don't put sealant everywhere on the block? He decided to put it everywhere (not excessively thick though) because he has little faith it will not leak otherwise.

 

[FLGatorgirl]

Back off, take a break, and finish next weekend. In prep for next weekend purchase an OEM oil pan gasket. Installing it will still be tricky but it will fit.

That might be tough. Scheduled to be back at the mechanic on Monday when AC parts are in and we are due out of town next weekend. He will be out of town most of the week, so our only real window is tomorrow or Monday. Unless we want to delay everything a few weeks .

 

[bentonrover]

Walk away is the key lol.

 

[Cruiserdrew]

I never had any luck installing it on the pan first. I stick it to the block with some permatex and then install the pan to the gasket.

 

[Output Shaft]

Delay.
Follow Godwin's advice and get the Toyota gasket.

In the meantime, take a look at the thread below by @Poser.

If you follow his procedure, it'll button right up.

Oil pan/ side cover gasket stuff....(FAQ)

 

[franklin40]

it took me three tries and three gaskets all OEM before I got mine sealed up (to be fair I guess the first go sealed but the pan leaked). so don't feel bad about having to try again. I had the gasket in backwards once. yes apparently there is a front and a back. I was able to do it on my own with lots of yelling etc. my kids know more words than they should and they were in the house!! take your time and don't panic about getting things in place to fast. the OEM gasket goo from toyota is also totally worth its price too. longer bolts on the corners can also help a bunch until you get the other bolts in place.

 

[FLGatorgirl]

it took me three tries and three gaskets all OEM before I got mine sealed up (to be fair I guess the first go sealed but the pan leaked). so don't feel bad about having to try again. I had the gasket in backwards once. yes apparently there is a front and a back. I was able to do it on my own with lots of yelling etc. my kids know more words than they should and they were in the house!! take your time and don't panic about getting things in place to fast. the OEM gasket goo from toyota is also totally worth its price too. longer bolts on the corners can also help a bunch until you get the other bolts in place.

Oh boy, how do you tell the front and back? I just looked and there is one end that has a little nipple (for lack of a better term) on one side and two nipples on the other side. The opposite end, no nipples.

 

[franklin40]

just make sure the holes line up before you put any goop on it and make sure it stays in the same orientation

 

[franklin40]

soooo... how'd it go?

 

[FLGatorgirl]

soooo... how'd it go?

Just got back from treating my husband to some cold beers and a prime rib dinner for working so hard on my truck all weekend. We got the pan in and no leaks so far! We did a trial run first with no sealant on the block and using the longer bolts to get everything tightened down better. I don't think we had the gasket the wrong way but we did have to drill out the cork a little bit in a few holes where it was a bit too tight. We have moved on to replacing the tie rods ends which are currently soaking in PB Blaster or something like that because they are totally rusted in place.

Knowing his distaste for rebuilding Toyota axles (we off-road rock raced for awhile), I asked my husband how many axles would he rebuild to not have to do another oil pan---and he said I would rebuild them as a full time job .

 

[cruisermatt]

For future reference, zip-ties around the gasket holes and pan are the way to go.

 

[Kaasdief]

Well done, looks like you nailed it.

 

[SteveH]

I never had any luck installing it on the pan first. I stick it to the block with some permatex and then install the pan to the gasket.

This, x2. My FJ62 required installing on the block - which I never did with my FJ40. Glad you got it solved. I'd much rather rebuild a knuckle!

 

[Cruzerman]

Have you checked out FelPro's SnapUps? Haven't used these myself, but they look like a good idea and other's have said good things about them.

 

[GLTHFJ60]

X3, install the gasket to the block first, then pan to the gasket.

Also, instead of the "right stuff" (which works great, but not ideal in this situation IMHO) use a product called Hylomar. I've yet to have something I sealed with hylomar leak. Rub it into the cork gasket and squirt a decent amount into the corners of the gasket.

 

[mongoose2231]

Funny this... I never had such an issue when I did my pan gasket . On the gasser that is. That was a CCOT rubberized gasket that sealed beautifully. The person who bought the truck said it never drips or leakes at all

 

[Godwin]

My first oil pan gasket replacement did not go well. I think I tried placing the gasket on the pan first and lifting all of that into place. Installed all the bolts, refilled with oil, and all seemed well. I had not fit the rear of the gasket into the groove properly and had a bad oil leak that fouled the clutch.