Rusted out oil pan?

So I have my KJ in for its annual inspection and emissions yesterday. I always take the opportunity to go out and talk to the technician (dealership) and look at it up on a lift. The under body has very little rust and I don't spot any leaks anywhere. So I ask him if he sees any obvious issues as I'm planning on keeping this vehicle for a while. He points out to me that the oil pan is extremely rusty and some time down the line he would replace it, and it would require dropping the front differential (?) It was definitely very rusted and it looked like more than surface rust around the seams to my untrained eye, so I believe him.

Anyone else had to replace their oil pan?

My ****** pan....it bubbled up and started to ooze out.

Looks like this was discussed here a few years ago:

http://www.jeepkj.com/forum/f196/oil-pan-corrosion-48553/

Too much darn salt in winter.
Here was my pan in May...just surface rust though. I take a quarter and hit it in the worst spots to see if it is just surface rust or worse.
If it is just surface rust there is no need to replace it. If it is large bubbling, and looks like it is about to leak well that is a different story. You might want to replace it then.
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Looks worse than it is each spring^ then.....it is time for sanding...& Paint once a year after power washing.
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After proper prep, I paint my oil pan annually, using a fast dry high temp paint & good for 1 more winter.
If I had to replace my oil pan, I would buy a new one & get the outside bedlined or something first!

I just replaced my ****** pan with a new Mopar a couple months back and now I noticed my oil pan is getting a little iffy. I think I'll follow LibertyTC's advice this spring. Looks like surface rust at this point but given the ****** pan was almost through may be replacing it too soon.

Just to chime in here... A front and trans skid helps a ton of keeping rock chips and salt off of your pan. Most mechanics are surprised when they get my jeep on the lift

The Mopar oil pan for the KJ is really lightweight thin metal.
I live in Atlantic Canada and the oil pan on my 04 Liberty rusted clean through. And yes I had a skid plate.

It's not an easy job to replace either. My mechanic had to lift the motor and drop the axle to be able to swap out the oil pans.

If I can find pics I'll post them later.

This was Randy's Oil Pan Tumor !:uhoh2:
http://www.jeepkj.com/forum/f196/oil-pan-corrosion-48553/
Do you have more photos..please share!arty52:

ya i got a new ****** pan waiting to go in. i feel if i look at my ****** pan now it might just fall apart into dust.......its that bad

Had mine done recently - also rusted out in salty Ontario. Tech had to drop the x-memb, raise the engine. PITA, but it's done.

Good luck - check out your engine mounts and have them replaced while they are in there if they are bad.

You may need an alignment depending on what is removed.

LibertyTC said:

This was Randy's Oil Pan Tumor !:uhoh2:
http://www.jeepkj.com/forum/f196/oil-pan-corrosion-48553/
Do you have more photos..please share!arty52:

Click to expand...

Looks like my gallbladder did when they finally got me to the hospital. Very messy business. :blah:

LibertyTC said:

This was Randy's Oil Pan Tumor !:uhoh2:

http://www.jeepkj.com/forum/f196/oil-pan-corrosion-48553/

Do you have more photos..please share!arty52:

Click to expand...

Yup, that's my oil pan.
I was wondering where I could find a pic of it. I completely forgot I posted it there.

My Jeep was in the garage all day and cost me a lot but seriously I couldn't have done it in my driveway.


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Mines rusted but I plan on repairing it. They are thin steel but you can clean off the rust and save the pan. You need a stiff wire brush, a scraper, scotch brite pads, your choice of JB weld, or repair kit for oil pans, high heat paint and some phosphoric acid solution (Jasco Prep and Primer is available at Lowes and works very well)

Wire brush it VERY well. IF there are no leaks it's easier. If you find a small leak don't panic. Take a dab of JB weld and stick it on the hole (it's temporary at the moment) Finish cleaning the rust off. Next wipe on the prep. Let it work for a while (longer is better) and then use a scotch brite to burnish the surface clean. Lightly brush it again and apply some more prep using a scotch brite to scrub it in. The acid will neutralize the rust and convert it to a stable compound. Now scuff the entire pan and wipe it clean. Use some of the JB weld or repair epoxty to fill the rust pits, then scuff the pan and apply a light coat of paint.

Now if you found a leak and plugged it you can repair it and not end up with oil all over the rusty areas! I like the repair kits as they include a good two part sealant and reinforcement material. Plus they don't require any heat. But a small torch and solder or brazing will also work. BUT if you use a torch DO NOT DRAIN THE OIL! The fumes and vapor in the pan could ignite/explode. If you have a way to purge the pan of fumes then drain the oil and purge. (I use CO2 from the MIG normally)

Repair the hole and clean the area and finish the painting.
It's also possible to repair the trans pan the same way.

Function > Form said:

Had mine done recently - also rusted out in salty Ontario. Tech had to drop the x-memb, raise the engine. PITA, but it's done.

Good luck - check out your engine mounts and have them replaced while they are in there if they are bad.

You may need an alignment depending on what is removed.

Click to expand...

Yup, been there, done that.

I'm not sure when I had to get my oil pan replaced on my 04 Liberty, maybe a couple of years ago. I've never seen anything
like it before. Okay I do live in Atlantic Canada but the oil pan on my my 95 YJ is just fine.

I had to take my Jeep to a garage where they lifted the engine and dropped the front axle. My biggest disappointment was to discover that the new Mopar oil pan was made of "pop can" thin metal.
No surprise that it rusted out so easily.
It better not rust out again or I just may have to do a SFA swap.
At least it would be easier to do.


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Cost me a bunch but got it done at the shop: Oil pan replacement with new gasket - $525

LibertyTC said:

This was Randy's Oil Pan Tumor !:uhoh2:
http://www.jeepkj.com/forum/f196/oil-pan-corrosion-48553/
Do you have more photos..please share!arty52:

Click to expand...

Hay-Seuss-Frikkin-Kristo.....that tumor looks about ready to pop.....send that pic to facebook and ask everyone to type "Amen".