any tips or tricks on replacing the oil pan gasket? i replaced the tranny pan gasket and filter with little to no problem but the oil pan.......doesnt look fun.

 

On your '91 you atleast don't have to remove the engine! LOL. Only problem is you'll probably have to jack up the engine to get the pan out due to clearance between the front of the pan and the front axle (being 4wd). If you do undertake this, make sure to not overtorque the pan bolts.

On my '00, the engine has to be removed (technically) because the transmission pan is a structural member, adding regidity to the bottom of the engine as well as the engine/transmission interface. Luckily for me, my pan gasket leak was simply due to loose pan bolts! But I also have an o-ring pan gasket.

 

get urself a manuel, haynes or chilton. im looking at chiltons right now and there is alot to remove to make it more accessable.

remove the skid plates, front axle sheild, transfer case sheild.(all if equipped)

remove the tranny hanger bolt and the exhaust pipe clamp from the cat, anddisconnect the pipes at the manifold, remove the pipes or slide them rearward.

from the front drive pinion, remove the shaft to pinion nuts/bolts and thenthe drive shaft.

remove the flywheel cover to engine braces and engine to chassis braces.

remove the flywheel cover, and the starter.

remove the steering shock absorber from the frame bracket, scribe a mark around the idler arm marking its position, then remove the steering gear bolts, the idler arm bolts and the arm. you may also have to remove the entire steering gear.

remove the front differential to bracket bolts from the side of the chassis, then pull the steering gear(if still in) and the linkage foward.

remove the motor mount bolts.

drain the oil by now, if not done so already.

using a vertical lift, raise the engine slightly.

then remove the pan bolts and the pan.

clean the entire pan thouroghly, using a solvent like seafoam.

while the pan isdrying apply a bead of rtv sealant along the bottom of the timing cover, the rear main bearing, the blocks sealing surface and of course the pans flange and to keep to the inside of the bolt holes.

install is the reverse of the removal.

let the rtv dry before adding oil, so go have urself a beer or two and then add oil, runn the truck to temperature and check for leaks.

hope this helps!!!

[IMG]local://upfiles/4216/6241119F79654A5B8F9232AD54E17DB5.jpg[/IMG]