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Rusty oil pan repair. #3009102 05/21/13 05:57 PM
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KrisZ Offline OP
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The oil pan on my 2003 Focus was really rusty. It did not look that bad when I was buying it, but looking at it more closely I knew something needed to be done about it if I wanted to have no nasty surprises.
I repaired it over the weekend. Here are some pics before, I treated the pan with Fluid Film before winter so it looks oily.





I cleaned off the big chunks of rust and treated the rest with rust dissolver gel. Really great stuff for automotive applications, as it is in a form of fairly thick gel so it stays on parts.



Here is how the pan looked like after several treatment coats. The grey patch in the middle is a cold weld, apparently resistant to all sorts of automotive fluids, that I had to apply after the pan sprung an oil leak when I tried to scrape off chunks of rust.
It was just a matter of time before the leak developed on its own. I hope the weld will hold.





And here is the finished product. I used Tremclad rust paint. I brushed on a thin first coat followed by a thicker second coat.




2015 Grand Caravan 3.6L - 35k miles.
2006 Mazda 3 2.0L - 186k miles
Re: Rusty oil pan repair. [Re: KrisZ] #3009109 05/21/13 06:04 PM
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tig1 Offline
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You need a new pan. It shouldn't be that hard to replace on your Focus.


2007 Ford Fusion 254,000 miles
M1 5-20HM
2017 Ford Fusion 86K
M1 0-20EP
10,000 mile OCIs on both engines
M1 ATF and M1 LV HP ATF
M1 10-30 in all OPE
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Re: Rusty oil pan repair. [Re: KrisZ] #3009110 05/21/13 06:04 PM
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spasm3 Offline
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I might just get a replacement pan and really clean and paint or coat it. That pan looks really bad.
Not sure if this fits yours but for the time and effort cleaning and repairing yours , this might be worth it.

http://www.ebay.com/itm/DORMAN-264-048-Oil-Pan-/390440630675?pt=Motors_Car_Truck_Parts_Accessories&fits=Year%3A2003|Make%3AFord|Model%3AFocus|Submodel%3ASVT&hash=item5ae8133993&vxp=mtr


13 elantra 81k 5w30 synpwr
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Re: Rusty oil pan repair. [Re: tig1] #3009134 05/21/13 06:23 PM
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Warstud Offline
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Originally Posted By: tig1
You need a new pan. It shouldn't be that hard to replace on your Focus.


^^^^^^^^^^^^^^^^^

Re: Rusty oil pan repair. [Re: KrisZ] #3009136 05/21/13 06:26 PM
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bdcardinal Offline
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Thats cool you repaired it, but just looking on rock auto, replacement pans go for $44-56. At that cost you have crossed the delta of repairing vs replacing.


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Re: Rusty oil pan repair. [Re: bdcardinal] #3009143 05/21/13 06:33 PM
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KrisZ Offline OP
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Originally Posted By: bdcardinal
Thats cool you repaired it, but just looking on rock auto, replacement pans go for $44-56. At that cost you have crossed the delta of repairing vs replacing.


Well, I figured that few bucks worth of materials and about two hours of my time would be worth a shot.
Besides, when things are this rusty, there is no knowing what else will fall apart when you start taking stuff apart. Also I'm in Canada and things are priced much higher than down south.


2015 Grand Caravan 3.6L - 35k miles.
2006 Mazda 3 2.0L - 186k miles
Re: Rusty oil pan repair. [Re: KrisZ] #3009175 05/21/13 07:18 PM
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Donald Offline
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When I had the engine replaced in my 2001 Jeep, they removed the oil pan to swap it and it was not in good shape so it was replaced.

The problem I see is if the pan develops a bad leak while you are driving, when the oil light comes on, it may be too late. To spend $50 or $100 to prevent that seems worth it. I suspect you have just bought some time with the repair and you will eventually need a new one. The issue is will it develop a slow leak and you will notice or will it leak badly and possibly ruin your engine.

Get the vehicle Krown'ed.


2015 Ford F-250 w/Powerstroke
2016 Subaru Crosstrek CVT (wife's)
Re: Rusty oil pan repair. [Re: KrisZ] #3009184 05/21/13 07:23 PM
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salesrep Offline
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I fought a rusted out oil pan on an 03 Dodge Ram ( a lil more than $45 or 50 to replace.,,,,this looks like a great attempt, hope it holds for you.


High quality Specialized Lubricants pay for themselves!
Re: Rusty oil pan repair. [Re: Warstud] #3009233 05/21/13 08:33 PM
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kschachn Offline
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+3. I hate groaty components on my car including old rusty bolts and nuts. I'd have to replace that pan pronto.

And how the heck did that get so nasty? The ones on my OLD cars (including the 19 year old BMW and especially my Sienna) look quite good still, even here in #saltWisconsin. That thing looks like it is 75 years old.

Originally Posted By: Warstud
Originally Posted By: tig1
You need a new pan. It shouldn't be that hard to replace on your Focus.


^^^^^^^^^^^^^^^^^


1994 BMW 530i, 252K
1996 Honda Accord, 288K
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2000 Toyota ECHO, 284K
Re: Rusty oil pan repair. [Re: kschachn] #3009235 05/21/13 08:36 PM
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motor_oil_madman Offline
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I'd say you missed the point of being able to repair it by about 3 years. Just throw a new one on there. It's going to bust a hole going down the road one day and there goes your engine.


2007.5 dodge cummins 6.7 liter. Chevron Delo400 15w40. 7000 mile or 250-300hr intervals.

Re: Rusty oil pan repair. [Re: KrisZ] #3009294 05/22/13 12:03 AM
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tbm3fan Offline
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Yikes, glad I don't live near any snow. You don't want to see a picture of the underside of my Focus. Still looks like 2004.


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2004 Focus
1998 Sable
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Re: Rusty oil pan repair. [Re: kschachn] #3009389 05/22/13 05:35 AM
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Trav Offline
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Quote:
And how the heck did that get so nasty? The ones on my OLD cars (including the 19 year old BMW and especially my Sienna) look quite good still, even here in #saltWisconsin. That thing looks like it is 75 years old.


Its the metal used. I see cars 20+ yrs old with nice pans and other that are much younger like this one.
I had an Expedition with a rotten frame and rockers but a great looking oil pan and have 2 Grand Prix that are rust free summer cars but both have badly rusted pans.
I don't think they make their own pans just outsource so god knows who made them and what cheap probably recycled metal they are made of.


ASE L1, Master. Deutsch Meisterbrief.
Re: Rusty oil pan repair. [Re: motor_oil_madman] #3009430 05/22/13 06:50 AM
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kschachn Offline
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Well the other thing is how much impact resistance that pan has if it's essentially being held together by paint. Several years ago someone dropped a ladder in construction traffic and I ran it over. It dented the oil pan but caused no leaks, I wonder how this pan would fare in the same instance.

Originally Posted By: motor_oil_madman
I'd say you missed the point of being able to repair it by about 3 years. Just throw a new one on there. It's going to bust a hole going down the road one day and there goes your engine.


1994 BMW 530i, 252K
1996 Honda Accord, 288K
1999 Toyota Sienna, 434K
2000 Toyota ECHO, 284K
Re: Rusty oil pan repair. [Re: KrisZ] #3009440 05/22/13 07:03 AM
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demarpaint Offline
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Good luck, you need a new oil pan. Now if its a beater like my Aerostar was and you really don't care, here's a trick I did thanks to Eljefino. The trick bought me about 18 months: Clean the pan the best you can with brake clean, remove loose [censored] being careful not to create a leak. Looks like you prepped it pretty well, just be sure its oil free. Get some lead flashing and form it to the contour of the oil pan. Apply some RTV sealant all over the molded flashing, pull it off and get more RTV sealant in there. Now put the molded flashing in place and seal all the edges of the flashing to the oil pan. Let it dry for about 24 hours, and then drive. The Sealant will eventually fully cure. For best results if the pan is leaking drain the oil before making the repair, the longer it drains the better. If you should scrape or wire brush and create leaks, you're screwed.


God Bless Our Troops

Re: Rusty oil pan repair. [Re: demarpaint] #3009464 05/22/13 07:39 AM
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Doog Offline
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Don't repair it...let it rot out until a pin hole leaks all the oil out and your engine seizes in the middle of Winter 150 miles from home. Then it will truly be Found On Roadside Dead LOL

Last edited by Doog; 05/22/13 07:40 AM.
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