Replacing Ford 6.4 Diesel Oil Pan: Step-By-Step Guide

The factory oil pan on the Ford 6.4L Powerstroke is known for developing rust over time, especially in colder climates. This can lead to oil leaks, which can be temporarily fixed with a reinforced epoxy, but the best solution is to install a new oil pan. This can be done without removing the engine, but it is a challenging task that requires careful manoeuvring and a variety of tools. The process involves draining the oil, removing the engine mounts, lifting the engine slightly, removing the oil pan bolts, sliding the pan, and then reversing these steps to install the new pan.

Drain the oil from the engine

To replace the oil pan on a Ford 6.4 diesel engine, the first step is to drain the oil from the engine. This is a crucial step as it ensures that you don't end up with oil spills when removing the oil pan. Here's a detailed guide on how to drain the oil effectively:

Park your Ford 6.4 diesel vehicle on a level surface and allow the engine to cool down. It's important to work on a level surface to ensure that the oil drains out completely.

Locate the oil drain plug. This is usually at the bottom of the engine, often at the lowest point of the oil pan. Place an appropriate drain pan or container with a capacity larger than your engine's oil capacity underneath the drain plug to catch the draining oil.

Before proceeding, ensure you have the necessary tools, such as a jack and jack stands or ramps if needed, and an oil filter wrench or oil filter socket that fits your Ford 6.4 diesel's oil filter.

Place the jack in the correct lifting point and raise the vehicle to gain access to the undercarriage. If you're using jack stands, place them on the recommended jacking points and ensure they're secure before proceeding. Alternatively, you can drive your vehicle onto ramps for easier access.

Once you have safe access to the undercarriage, locate the oil drain plug again and place the drain pan or container directly underneath it. Have some rags or absorbent material nearby to wipe off any spilled oil.

Using the appropriate-sized wrench or socket, loosen and remove the oil drain plug. Be careful when removing the plug, as hot oil may start draining immediately. Allow the oil to drain completely. This may take several minutes, depending on the temperature of the oil and the size of your drain pan.

While the oil is draining, take the opportunity to inspect the oil plug and oil pan for any signs of damage, rust, or debris. Also, check the tightness of other accessible bolts and components.

After the oil has finished draining, carefully tighten the oil drain plug back into place. Ensure it's hand-tight, then use your wrench to gently snug it up, being careful not to overtighten it. Overtightening can damage the oil pan threads or even strip them, leading to potential leaks.

Lower the vehicle from the jack stands or ramps, ensuring it's still on a level surface. Now, locate and remove the oil filter. The oil filter in your Ford 6.4 diesel is typically located near the front or side of the engine. Use your oil filter wrench or oil filter socket to remove it. Have rags or absorbent material ready to catch any residual oil that may spill.

Once the oil filter is removed, clean the mounting surface of the engine block to ensure there is no dirt or debris that could contaminate the new oil. You can use an old rag or a specialised tool like a gasket scraper for this task.

Apply a thin coat of new engine oil to the rubber gasket of your new oil filter. This will help create a better seal and make removal easier during your next oil change.

Install the new oil filter by hand-tightening it first and then giving it a quarter to a half-turn with the oil filter wrench or socket. Be careful not to overtighten, as this can lead to difficulty in removal and potential damage to the oil filter housing.

With the new oil filter in place, add fresh engine oil of the recommended type and grade for your Ford 6.4 diesel engine. Consult your owner's manual or a trusted mechanic if you're unsure about the correct oil type and capacity for your vehicle.

Use the dipstick to check the oil level after adding oil. Ensure that it's at the 'Full' mark or within the recommended range. If you've added too much oil, you can drain a small amount, and if you've added too little, top it off accordingly.

Finally, start the engine and check for any leaks. Keep an eye on the oil pressure gauge or warning light to ensure that the oil pressure is within the normal range. If there are no leaks and the oil pressure is stable, your oil drain and refill process is complete.

Remove the oil pan drain plug

To remove the oil pan drain plug, you must first drain the oil from the engine. Place an appropriate drain pan underneath to catch the oil and remove the oil pan drain plug.

There are a number of reasons why the oil drain plug might be stuck. The most common cause is sludge formation around the plug, which occurs when engine oil is left too long and begins to oxidise under high temperatures. This sludge, a mixture of engine oil, dirt, carbon, metallic particles, water, and fuel, hardens and makes it difficult to remove the plug.

If you find yourself in this situation, there are several methods you can try to remove the stuck oil drain plug:

• Warm up the car: Let the car idle or take it for a short drive, then locate the oil drain plug and try to move it clockwise or counterclockwise until it loosens.
• Use a socket wrench: Get the proper socket size that matches your oil drain plug and use it to remove the plug. A longer handle will provide more torque and make your task easier.
• Use a hammer: If the previous method fails, try tapping the oil drain plug gently with a hammer. Be careful not to damage the plug or its teeth, then try again with the socket wrench.
• Use a rust remover or lubricant: Spray some rust remover or lubricant on the oil drain plug and let it react for a few minutes before attempting to remove the plug again with a socket wrench or another tool.

If your oil drain plug is stripped, you may need to try different methods to remove it. Here are some suggestions:

• Use a wrench, socket and ratchet, or vice grips: The right-sized wrench or socket and ratchet should be able to remove a stripped oil pan bolt. You may need to apply upward force or wedge the bolt out with a screwdriver. Vice grips can also be attached to the bolt and turned to help remove it.
• Use a bolt extractor socket: A bolt extractor socket is designed to grip and release the socket. You may need to gently hammer it on and then turn it with a ratchet to release the bolt.
• Drill the bolt out: If the bolt is still stuck, try drilling it out with a small drill bit. Drilling in reverse may help pull the bolt out. You may need to drill a larger hole and use a bolt extractor.

Once you have successfully removed the oil drain plug, you can continue with the process of replacing the oil pan in your Ford 6.4 diesel engine.

Remove nuts securing engine mounts

To remove the nuts securing the engine mounts of a Ford 6.4L Powerstroke, first drain the oil from the engine. Position an appropriate drain pan underneath to catch the oil, then remove the oil pan drain plug. Next, locate the nuts securing the engine mounts to the front crossmember (two per side, later years have four nuts per side). Remove these nuts. For trucks with automatic transmissions, remove the horizontal bolt securing the trans cooler lines above the oil pan. After that, remove the radiator hold-down brackets that are bolted to the radiator support.

Now you can start to raise the front of the engine. Using a floor jack and a piece of wood, slowly lift the front of the engine by raising the bottom of the harmonic balancer. Removing the steering linkage can give you more access to the balancer, as the clearance can be tight. Instead of a floor jack, you could use an engine hoist and lift the engine from above. Keep an eye on the top of the turbo while doing this, as it is a tight fit and will begin to contact the firewall/cowl area.

Remove radiator hold-down brackets

To remove radiator hold-down brackets, you will need to first drain the oil from the engine. With an appropriate drain pan positioned underneath to catch the oil, remove the oil pan drain plug. Next, locate and remove the nuts securing the engine mounts to the front crossmember.

For trucks equipped with an automatic transmission, remove the horizontal bolt securing the trans cooler lines above the oil pan. After that, you can remove the radiator hold-down brackets that are bolted to the radiator support.

• Turn off the hot water and leave it to cool down for half an hour or so. This will allow you time to prepare for your radiator installation and removal.
• Turn off the radiator you are replacing by turning the control valve clockwise. There should also be a protective cap, known as the lock-shield valve, at the far end of the radiator. Remove the cap and close this valve using an adjustable spanner, also turning it clockwise.
• Bleed the radiator to get out any excess water. Turn the key at the far top corner and have a cloth or tray ready to catch any dirty water that might drain from the radiator.
• Place a container under the control valve ready for the excess water. Use a wrench to grip the valve, hold it in place, and loosen the nut that connects the valve to the radiator.
• Vent the radiator to break the vacuum inside and allow the water to flow out of the control valve. You will need a radiator key to open the bleed valve to do this. Make sure you allow the radiator to drain fully.
• Once you have drained the radiator, you will need to remove it. To do this, loosen and undo the nut that connects the lock-shield valve to the adaptor in the radiator. You might need some assistance here. Use your radiator key to close the bleed valve.
• The radiator is now ready to be removed. Grip the valve assembly at the bottom of the model with a steady wrench to prevent it from being pulled loose along with the unit itself, then undo the necessary nuts and bolts before hoisting the radiator from the brackets on the wall.
• Now that your radiator is removed, you may need to drain any excess water still inside; simply hold the radiator at an angle to release all the remaining water.
• Remove the radiator brackets, as these will not be needed when fitting the Rotarad kits.

Raise the front of the engine

To replace the oil pan on a Ford 6.4 diesel engine, you don't need to remove the engine. Instead, you can simply raise the front of the engine slightly to gain the necessary clearance. Here's a detailed guide on how to do this:

First, make sure you have the necessary tools and equipment, including a floor jack, a piece of wood, and, optionally, an engine hoist. Place the floor jack with the wood on top under the engine, positioning it on the bottom of the harmonic balancer. If you wish to lift the engine from above, you can use an engine hoist instead.

Next, begin the process of raising the front of the engine. This can be done by slowly jacking up the engine using the floor jack. Keep a close eye on the turbo while doing this, as the fit is very tight, and it will begin to contact the firewall/cowl area. Ensure that you do not lift the engine too high, as this can cause damage to the transmission bell housing.

Once you have raised the front of the engine a few inches, you can proceed to the next steps of the oil pan replacement process, such as removing the oil pan bolts and sliding the pan rearward.

It is important to note that this process may vary slightly depending on the model year of your Ford 6.4 diesel engine. Additionally, always exercise caution when working on your vehicle and refer to a professional mechanic if you are unsure about any steps.

Frequently asked questions