Update on the 3rd Attempt at Leak Repair
On the second attempt to repair my oil pan leak, they installed a new pan. I picked it up and have run it for a few days. It's leaking worse now that it ever has, so that attempt at repair was definitely not successful.
I stopped by the dealership today and had a good chat with the service manager. The attitudes were positive, but, unfortunately, no real breakthrough or insights into why the first two attempts at repair were unsuccessful. I did suggest that on the next attempt they drive the truck a few miles with the skid plates off and then recheck for leaks before they declare the repair complete.
I scheduled my truck back to the shop on Monday for the third repair attempt.
This is getting tiring.
Picked up my truck yesterday. Here is what was done on the 3rd repair attempt:
1. Oil pan removed and allowed to sit for 18 hrs so oil could drain from inside walls of engine block.
2. Clean the sealing surfaces of all oil (I hope).
3. Install pan (new on second attempt, so slightly used at this point) with recommended Ford sealant
4. Let sit for 24 hours for sealant to cure, skid plates not installed
5. Dealer drove truck several miles and checked for leaks with none found
6. Cleaned transmission pan of engine oil blown back on it, also cleaned top of skid plates and reinstalled
7. I asked them to put the truck on the lift before I left with it so I could get a look (much better than crawling under it)
Note that this approach is a 3 day repair.
I drove it home and checked for leaks. So far so good, but that's a short trip. Fingers crossed!