Introduction:
If you own a Powerstroke diesel, chances are you’ve either dealt with an oil pan leak or will at some point. It’s a common problem and diesel repair across the 7.3L, 6.0L, 6.4L, and 6.7L engines, and fixing it isn’t always straightforward. Let’s break down why oil pan leaks happen, the symptoms, and the best ways to repair and prevent them.
Why Do Powerstroke Oil Pans Leak?
Several factors contribute to oil pan leaks on Powerstroke engines:
Vibration and Heat Cycles – Diesel engines produce significant vibration and extreme temperature fluctuations, which can cause the sealant to break down.
Sealing Surface Issues – Over time, the factory sealant can degrade, crack, or lose adhesion, leading to leaks.
Rust and Corrosion – The oil pan on the 7.3L and 6.0L Powerstroke, in particular, is prone to rust, especially in salt-heavy climates.
Symptoms of an Oil Pan Leak
Not sure if your Powerstroke is leaking oil from the pan? Here are the common signs:
- Oil spots under the truck – The most obvious symptom is oil dripping from the bottom of the engine.
- Low oil levels – If you're constantly adding oil, a slow pan leak might be the culprit.
- Visible oil seepage around the oil pan – Check for oil collecting around the edges of the oil pan or on nearby components.
- Burning oil smell – If oil drips onto hot exhaust components, you may notice a burning smell while driving.
How to Fix a Powerstroke Oil Pan Leak
1. Resealing the Oil Pan
For most 7.3L and 6.0L Powerstroke leaks, the best fix is to remove the pan and reseal it properly. Unfortunately, this diesel repair isn’t a simple job—it requires lifting the engine or removing it entirely in some cases. This requires the truck's Cab to be removed.
- OEM Ford Gray RTV Sealant – Ford doesn’t use a gasket; instead, they use RTV (Room Temperature Vulcanizing) sealant to create a leak-proof bond.
- Thorough Cleaning is Key – All old sealant must be removed, and the sealing surface must be completely free of oil before applying new RTV.
6.7 Upper and Lower Oil Pans - Double the Sealing Surfaces, Double the trouble.
2. Replacing a Rusted or Damaged Oil Pan
If rust has eaten through the oil pan (a common issue on 7.3L and 6.0L models), the only solution is a full replacement.
3. Using a Gasketed Oil Pan VS RTV Silicon.
Companies like Morosso Make Actual Gaskets for the oil pan instead of silicon. We have tested this to be the best solution for a leak free seal. We've also installed the early model 6.7 pan that has a gasket built in on newer model trucks eliminating the use of RTV.
Final Thoughts
If you notice an oil leak on your Powerstroke diesel, don’t ignore it. While it might start as a small drip, over time, it can lead to bigger issues like low oil pressure, contamination, and potential engine damage. Fixing an oil pan leak the right way might be time-consuming, but it’s worth it for long-term reliability.
