The oil pan has leaked in the Mustang since I rebuilt the engine several years ago. At first, I thought the engine was leaking from the rear seal as that is where the majority of the oil accumulated. Over time, I noticed it was actually leaking about 2/3rds of the way back on the passenger side of the oil pan.
This weekend I decided to take the oil pan off to repair the leak. I used a Fel Pro one piece pan gasket without RTV during the rebuild and hoped to reuse it. Unfortunately, it ripped when I removed the oil pan from the Mustang.
I examined the oil pan and found the mounting flange was not flat. The unevenness around the bolt holes can be barely seen in the following picture.
I spent last Sunday straightening the mounting flange all the way around. Once it was a flat as possible, I stripped the entire pan and repainted it with a fresh coat of Duplicolor Engine Enamel primer and Ford Blue paint (DE1606).
I purchased another FelPro OS13260T gasket at O'Reilly and then installed the oil pan this weekend. It was time for an oil change so I put on a new Fram oil filter and some 10w30 Brad Penn oil. It has rained for days so I've not driven it yet but I'm hopeful this eliminates the oil leak.
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