Upper Oil Pan Leak

[Guggenheim99]

About a 1 1/2 years ago I removed my front differential to reseal it and while I was at it I replaced the upper oil pan gasket that was leaking. Replaced it with a FelPro one. Applied the sealant in the spots called out and installed it. Didn't leak for a while then noticed a leak from the rear of the engine again. Just recently had the cab off for frame swap so I pulled the engine to do a timing job (rear guide was completely broken) Anyways when I got the flex plate off I saw oil puddling between the seam for the block and upper pan where the gasket sits in (see picture) I replaced the gasket again with another FelPro since the pan was off for the timing job and I had it on the stand anyway. Applied the sealant in the corners like instructed (see photo) and reinstall pan, reinstall engine and finish frame swap Saturday. By Monday I could already start seeing a drip forming when I was doing my alignment. By today it's a full on drip from the bellhousing. I also did rear main seal, jackshaft plug, and the the seal on the rear cassette bolt is new. I feel if the rear main seal was leaking, it would have done it not long after the first start and been dumping. Kind of at a loss. I put sealant in the correct corners. I know it isn't a sealant issue since the front bearing cap and front cover t-joints are not leaking and the same sealant is there. I have not pulled the transmission to verify where it's coming from. That is alot of work but may be necessary. Maybe I can pull the starter and sneak a borescope in there but the bell housing plate is wedged in there so I may not be able to see. Any ideas? Should I buy a Ford gasket this time and try again? Quite aggravating doing all this work and it still leaks. Thanks

 

[franklin2]

Go over all the bolts again. Do not over tighten them but make sure they are as tight as you can get them with putting your hand over the head of the ratchet. These gaskets like to shrink after you run them a week or two.