This oil pan repair kit covers the 7.3 L Ford Powerstroke for the following years: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003. Please include the year model and build date during checkout.This kit is very easy to install yourself, at home, over the weekend. No truck lift is needed to complete the installation of the kit. No special tools are needed but an angle grinder does help the process go much faster.
Oil Pan Repair Kit Cost = $295
Step 1: Clean Pan
Drain Oil from the truck
Remove the oil filter and save for later
Wrap the oil filter housing with a rag
COMPLETELY clean the outside of the pan with 36 grit sand paper and an angle grinder
Don’t worry about holes in the pan they will be covered up with epoxy
Wipe the entire pan with Acetone and be sure that there is NO oil dripping from the drain plug
INSERT the oil drain plug back into the pan
Step 2: Mix Epoxy
Dry fit the shell onto the clean oil pan
Acetone the inside of the shell
Prepare a surface to mix the epoxy on. Ideally this a movable and solid surface.
Use a solid putty knife or scrap piece of metal/wood to mix the epoxy
Work time with the epoxy is roughly 30 minutes. Take your time mixing it and make that it is 100% blended.
Step 3: Prep for Install
Have everything prepped and ready to cover the pan
Clean the pan with acetone again
Clean the shell with acetone again
Have jack and wooden blocks ready under the truck
Clean the old oil filter and have it ready under the truck (you’ll use this to brace the wedge)
Step 4: Cover the Pan
Make sure the oil drain plug has been re-installed
COVER the oil pan with the epoxy making sure to cover all areas that were prepped
Make sure to use 100% of the epoxy
Install the shell and press up evenly by hand
Step 5: Setup Blocks
Place the jack underneath and LIGHTLY raise to hold the shell in place. Use wooden blocks to get around the drain plug.
Install the old oil filter
Insert wedge between the oil filter and the pan saver shell
Wait 30 hours minimum for the epoxy to cure. Wait longer if it’s cold outside.
After 30 hours has passed, remove the jack, blocks, oil filter and cut the epoxy off the drain plug.
Install new oil filter, fill with oil, crank the truck, let it warm up and enjoy your leak free oil pan.
The estimate to fix my truck was over $2,000. With very few tools and a Saturday afternoon I managed to patch up my pan for a fraction of the price. It’s been 3 years now and I still don’t see any spots in the driveway. This kit saved me well over a grand!