The oil pan is such a frustrating topic to me. Moroso makes a soild one piece oil pan gasket which is an option, and which I was going to use when I had my motor out but changed my mind. You can read my review of it here:
I ended up using the Ford TA31 grey sealant, but I did not turn the engine upside down, I did it with it right side up on an engine stand. Not sure if this was the cause or if I just didn't apply enough sealant, but I've had issues with it continuing to leak in both the rear and front. In the rear, after I removed the trans, I could see I missed a tiny spot with sealant, and in the front, I have some very light seepage near the bottom of the curve that meets the front engine cover. In both cases, I've cut off the excess sealant original sealant and applied more sealant externally after a good cleaning with brake cleaner and compressed air. I believe I solved the problem in the rear, and the verdict is still open on the front, as I just did that one last weekend and haven't driven it yet.
If you were to decide to try the Moroso route, I think it might be possible to do it without removing the engine - you'd have to remove the turbo and a lot of other stuff off of the top and front of the engine and disconnect your water hoses for sure, and I'm sure several other things I cant think of off the top of my head. As KL said, removing the old sealant would be difficult, BUT I disagree that removing the pan itself is that difficult, if you have the space to cut it well with a box cutter and/or razor blade, it comes off not too bad with some light prying. And since the main thing that keeps the pan from coming out with the engine lifted up is the oil pickup tube, if you could raise the engine enough to unbolt the pickup tube (two bolts in the front, and one bracket bolt in the back) I would think you could pull the pan out entirely from between the block and the crossmember to enable a thorough cleaning? I just don't see why that wouldn't work, but I've never heard of anyone whose tried it.
Plus I'd sure like to hear from someone who had a successful installation of the Moroso oil pan, as I didnt get to that point, but maybe I should have.
2000 F250 Ext Cab Longbed 7.3 4x4 ZF6 "The Pride of America" - AEM air filter, BTM exhaust, CNC Fab HPOP lines, CNC Fab 4-line stainless fuel lines, Fluidampr harmonic balancer, LuK improved clutch kit, Melling LPOP, DieselSite coolant filter, 203* thermostat in billet housing, 3 gauges (boost, pyro, fuel pressure) in pillar mount pod, AIH delete, EBPV delete, CCV mod, Zoodad mod, Glow Plug Relay relocation mod, Hutch mod, Harpoon mod, MileMarker manual locking hubs.
Last edited by SuperDutyTrooper; 04-03-2016 at 10:02 PM.