Ford Freestar, Monterey 2004-2006

Oil Pan

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Removal & Installation




CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner, should be used.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely on jackstands.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the oil filter.
  8.  
  9. Remove the dual converter Y-pipe assembly.
  10.  
  11. Remove the starter motor.
  12.  
  13. Remove the engine rear plate/converter housing cover.
  14.  
  15. Remove the 3 oil pan-to-transaxle bolts.
  16.  
  17. Remove the retaining bolts and remove the oil pan.
  18.  

To install:

  1. Clean the gasket mating surfaces thoroughly.
  2.  
  3. Trial fit the oil pan to the cylinder block. Ensure that enough clearance has been provided to allow the oil pan to be installed without sealant being scraped off when pan is positioned under the engine.
  4.  
  5. Apply a bead of silicone sealer to the oil pan flange. Also apply a bead of sealer to the front cover/cylinder block joint and fill the grooves on both sides of the rear main seal cap.
    NOTE
    When using silicone rubber sealer, assembly must occur within 5 minutes after sealer application. After this time, the sealer may start to harden and its sealing effectiveness may be reduced.

  6.  
  7. Install the oil pan and secure to the block with the attaching bolts. Tighten the bolts in sequence to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Oil pan bolt torque sequence-3.9L and 4.2L engines

  8.  
  9. Install the oil pan-to-transaxle bolts and tighten to 33 ft. lbs. (45 Nm).
  10.  
  11. Install a new oil filter.
  12.  
  13. Install the engine rear plate/converter housing cover.
  14.  
  15. Install the starter motor.
  16.  
  17. Install the Y-pipe converter assembly.
  18.  
  19. Lower the vehicle.
  20.  
  21. Fill the engine with the proper type and amount of clean oil.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Start the engine and check for leaks.
  26.  

 
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