Replacing the Oil Pan Gasket Without Removing the Oil Pan on my '97 2.5L Jeep Wrangler

Originally posted December 27, 2020
Project TJ - working on my 1997 Jeep Wrangler. It's the SE version of a TJ with a 2.5L four cylinder and a standard transmission. At the time of making this video, the Jeep had ~204,000 miles on it.

This Jeep had a number of issues when I bought it. In this video, I go after the Jeep's oil leak. I’d previously replaced the valve cover gasket but that didn’t resolve the leak (not that I thought it would). There is so much oil on the oil pan and blowback on the transmission that I’m pretty sure it’s the oil pan gasket and not the rear main seal. Since the gasket is cheaper and easier, I’m going with that next.

I couldn’t find much help on how to do it on YouTube so I thought I’d make this a tutorial video. Had I referenced the service manual, I would have noticed the line that says “Using the jack stand, raise the engine until adequate clearance is obtained to remove the oil pan.” (In other words, “If you don’t raise the engine you won’t be able to get the oil pan out.”)
In the video, you’ll notice that I discover that the exhaust crossover is in the way. My thought is that the exhaust would have to come out, but the service manual has a better, alternate way. Next time, I’ll try that!

UPDATE: You can also disconnect the exhaust down pipe from the exhaust manifold, which will drop the exhaust and should give you the clearance needed. It's "just" two nuts, but they are usually heavily rusted into place. If you go this path, best to have a spare 2 nuts and bolts in the event you break them. Check out my exhaust replacement video:    • Replacing the Exhaust on a Jeep TJ 2....  

I’m able to replace the gasket without removing the oil pan. We’ll have to see if the replacement holds and if it also stops my oil leak (so far so good, 2 days after the repair). This was a good learning experience, for sure. It’s also yet another story where the initial plan is perfect until you start implementing it.

If you want to continue to learn from my adventures, and missteps, please subscribe to the channel. Any comments and questions are also welcome! Thanks for watching.

Parts (Amazon Affiliate links):
10w-30 motor oil (4 quarts): https://amzn.to/3mbvqUT
Fel-Pro oil pan gasket: https://amzn.to/3mhNvkt

Tools:
Safety Glasses (watch for falling rust, dirt, and grime)
7/16” deep socket (19 bolts, 1/4-20 threads)
1/2" deep socket (4 bolts, 5/16-18 threads, really only need the deep socket on 1 bolt)
18mm socket and wrench
E12 Torx socket for factory starter bolts
Extensions
Ratchet
Torque Wrench (in-lbs or Nm)

Torques:
7/16” hex bolts/studs (total 19) = 84 in-lbs
1/2" hex bolts/studs (total 4) = 132 in-lbs

Video Links:
Valve Cover Gasket:    • Valve Cover Gasket Replacement on my ...  
Starter Replacement:    • Knowing Your Limits and Taking the TJ...  

Intro (0:00)
Removing the Starter (1:46)
Removing Transmission/Flywheel Access Cover (3:47)
Removing Oil Pan Bolts (5:05)
A Minor Issue (7:49)
Mid-Maintenance Update (9:38)
Torquing the Pan Bolts (11:54)
Closing Thoughts (12:33)


Disclaimers:
This video is NOT sponsored by any of the brands mentioned throughout this video or video description. All thoughts mentioned are my own. Some links provided are affiliate links. They do not cost you anything, but I make a small percentage from the sale. Honesty is key on my channel, thank you for supporting me!

I am a Do It Yourself, also known as DIY, mechanic. I am NOT a professional mechanic. I do not have any formal training in the automotive field. I assume no liability for anything you choose to do to your car/vehicle or equipment before or after watching one of my videos. All DIY repairs or modifications you perform are made at your own risk. Sometimes, even if you've done everything the right way, you can destroy or damage one or more things on your car or equipment. You must understand this, but by leveraging knowledge and patience, the probability of encountering one or more problems can be reduced.

Also, if for some unfortunate reason, I do give incorrect instructions and something breaks because you followed my instructions, I will NOT reimburse or pay in any way for whatever cost that may be incurred due to following my wrong instructions.
Lastly, please don't do anything to your vehicle or equipment unless you yourself feel comfortable and confident in doing so.