Replacing Oil Pan Gasket In 2008 Ford Fusion: Step-By-Step Guide

The oil pan gasket on a 2008 Ford Fusion is an important component that seals the oil pan to the bottom of the engine. Over time, the gasket can degrade and start leaking oil, leading to potential engine damage. Replacing the oil pan gasket involves draining the oil, removing the oil pan and gasket, scraping off the old gasket, and installing a new gasket with a high-temperature sealant. The average cost for this repair is between $461 and $541, with labour costs estimated between $308 and $389.

Drain all the oil from the car

To drain all the oil from your 2008 Ford Fusion, follow these steps:

First, warm up the engine by driving it a short distance. You don't want the engine to be too hot, as you'll be working near a hot exhaust line. Pull the car onto ramps and put the transmission in park, setting the parking brake.

Place an oil drain pan under the car, under the oil pan drain plug. It is recommended to put old newspaper under the pan to catch any splashes and drips. Using a 3/8 drive with a 15mm socket, remove the drain plug and let the crankcase drain into the pan.

After the oil has drained, wipe the drain plug and mating surfaces clean, then reinstall the plug. Torque the drain plug to 19 ft-lb.

Now you can remove the filter. This is located towards the front of the car, between the Air Conditioner compressor and one of the exhaust lines. There is very little maneuvering room, so it is recommended to use an End Cap Filter Wrench. The first time you change the oil, the filter will be on extremely tight. A breaker bar will provide the necessary leverage to remove it.

Once the filter is removed, inspect the old filter and mating surface of the engine to ensure the gasket did not remain behind. Clean the filter mounting surface of the engine with a clean paper towel or rag.

Now you have drained all the oil from the car, and can proceed to the next steps of changing the oil pan gasket.

Remove the oil pan

To remove the oil pan from a 2008 Ford Fusion, follow these steps:

First, drain all the oil from the car. Next, locate the oil pan and remove it with basic tools. The size of the socket required is not known, but you can determine this by checking the size of the bolts on the oil pan. Once the oil pan is removed, scrape off the old gasket.

Be careful not to damage the oil pump, which is protected by the oil pan.

Scrape off the old gasket

To scrape off the old gasket on your 2008 Ford Fusion, start by draining all the oil from your car. Once the oil is drained, remove the oil pan from the engine. Be careful not to bend the oil pan when removing it. Attempting to pry it loose with a screwdriver can cause the mounting surface to bend. Instead, use a mallet to gently tap the pan if it doesn't come off easily. Make sure all the bolts are removed before taking off the pan.

With the oil pan removed, it's time to scrape off the old gasket. Use a plastic or composite scraper to remove the remnants of the gasket. Do not use metal tools as they can damage the soft aluminium engine surface and create an improper seal, leading to oil leaks. Hold the scraper at a steep angle, nearly parallel to the surface, and slowly scrape away the gasket. You can also try chipping at the gasket by holding the scraper a few inches away and quickly jabbing at it like an ice pick. Alternatively, hold the scraper perpendicular to the surface and quickly slide it back and forth. Once most of the gasket is removed, use a corner of the scraper to get rid of the remaining bits. Be patient, as this process can be time-consuming.

If you're having trouble removing the gasket, you can try using a solvent or gasket remover solution. Soak the gasket with brake fluid, acetone, diesel, kerosene, or CRC Technician Grade gasket remover. You can also use a razor blade gasket scraper with the dripping oil as a lubricant. Just be cautious not to let the oil catch fire. Additionally, a 3M Bristle Disc attached to a rotary tool can be effective in cutting through the gasket. However, be gentle if using a green disc on aluminium, as it can cause depressions.

Apply a new gasket with sealant

To apply a new gasket with sealant to your 2008 Ford Fusion, follow these steps:

First, ensure that you have drained the oil from the car and removed the oil pan. Next, scrape off the old gasket from the oil pan. Compare the new gasket with the old one to ensure that you have the correct replacement.

Now, you can apply the new gasket. Apply a bead of high-temperature gasket sealant to the oil pan where the new gasket will sit. Work the sealant into the groove with a dental pick or similar tool if necessary. Carefully place the new gasket onto the oil pan, ensuring that it is correctly positioned and does not move during the curing process.

Finally, torque the bolts on the oil pan to the manufacturer's specifications. Allow the sealant to cure for the recommended time before refilling the engine with oil and checking for leaks.

Bolt the new gasket and refill with oil

Once you have your new gasket, it's time to bolt it into place and refill your engine with oil.

Start by placing the gasket on top of the pan. Then, insert a couple of bolts through the pan to hold the gasket in place. Thread those bolts into the engine by hand. Once the pan is in place, you can thread the rest of the bolts in by hand. Next, use a torque wrench to tighten the bolts to the manufacturer's specification.

Now, carefully remove the jack stands and lower the vehicle. Once you've done that, refill the engine with the correct amount of fresh oil. Reconnect the negative battery cable, then start your engine and carefully check for leaks.

Frequently asked questions