Oil Pan Won’t go back in HELP

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07-12-2018 | 08:01 PM

WavyXj

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Newbie

Joined: Jul 2018

Posts: 3

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Model: Cherokee (XJ)

Oil Pan Won’t go back in HELP

Hi I just recently bought a 1991 Jeep XJ with 88,000 original miles on it in January. I assume it has been sitting for quiet some time because a lot of the gaskets are going which leads me to this problem. I was leaking massive amounts of oil so I got underneath to inspect & seen that oil was coming from the oil pan & transfer case, it would leak on to the down pipe & create tons of smoke when the exhaust heated up. I have the XJ jacked up on the frame rails so the axle is hanging down a lot but now I’m trying to install the new oil pan & it’s not fitting. Is the axle dropped too much? I heard this on another post but didn’t think that could be a actual thing. My downpipe is rusted to the converter so I can’t take off the down pipe with out cutting it off. I also have two bottle jacks on the axle to the frame to drop it even more but it’s still not clearing the axle. I know there is a lot of info out there but I’ve tried everything expect taking apart the axle which I thought was overkill. I have the fel pro oil pan but could it be to big? I’m new to posting on the forms & any advice would help me out a lot, thanks!!

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07-12-2018 | 10:51 PM

dzywicki

Senior Member

Joined: Jul 2012

Posts: 710

Likes: 76

Model: Cherokee

Try jacking up the axle under the diff. It's counter intuitive, but it moves the axle forward and gives enough room to get the pan in around the axle. I used dental floss to hold the pan gasket in place while fitting it up. I did have to put the oil pump in the pan, fit the pan around the axle and then bolt the oil pump in to make it all fit. I also packed the oil pump with vaseline and had instant oil pressure on startup.

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07-12-2018 | 10:59 PM

WavyXj

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Newbie

Joined: Jul 2018

Posts: 3

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Model: Cherokee (XJ)

Thanks I really appreciate the advice! This job as been a real PITA since day 1.

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07-13-2018 | 01:53 AM

5-Speed

::CF Moderator::

Joined: Dec 2016

Posts: 3,498

Likes: 397

From: SoCal

Year: 1987

Model: Cherokee (XJ)

If your XJ is stock height, it is a pain. My lifted one, no problem. Even left it at ride height to do the job. Stock one, nightmare. I ended up pretty much dropping the front axle out but it was no big deal since I was doing new arms and bushings at the same time.

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07-13-2018 | 03:00 AM

nickfancher1

Member

Joined: Aug 2014

Posts: 132

Likes: 2

From: Phoenix, AZ

Year: 1996

Model: Cherokee

Engine: 4.0L

Yeah you need to lift the front axle a little bit with the jacks, might need to lift one aid whither than the other so you can twist the pan in there.

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07-13-2018 | 08:23 AM

CRLAMBERTJR

Senior Member

Joined: Feb 2018

Posts: 534

Likes: 2

From: Kentucky

Year: 1999

Model: Cherokee(XJ)

Engine: 4.0L I-6

My 99 has no lift. I didn't drop the axle much, just had both shocks removed. I got the pan out that way. To put it back, I removed the left end of the steering damper, went right in !!!

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07-13-2018 | 10:12 PM

WavyXj

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Newbie

Joined: Jul 2018

Posts: 3

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Model: Cherokee (XJ)

I got it !!! Finally after three days of just needing the oil pan on! It turns out I did have the axle droped way too much. I used jack stands under the frame rails so the Jeep was off the ground pretty high then jacked up the axle until the i was able to wiggle in the pan. I hope this post will help someone in the future. I didn’t need to take off anything besides the starter & the passenger side (I want to say transmission or transfer axe bolt) thanks to everyone who took the time to post!

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