Rear main seal issues. (vid link)

[fairmontwagon]

I bought a 1981 Ford Fairmont wagon with the 200ci about 3 months ago for $500, odometer said it had 37,000+ miles and I'm assuming it's around 237,000 miles. Upon purchase it was leaking oil from what I thought was the rear main seal to the tune of a quart every 40 miles or so. I've changed rear main seals on Chevy's with the single piece and it was always a breeze, so when I got this Fairmont I thought it'd be the same. I was wrong.
I came across this forum and learned WSA111 method explained here:
http://fordsix.com/forum/viewtopic.php?t=19247
A week later, I followed everything except the bit about the sealant on the flex plate bolts, because I'm doing this with the engine in the car and I can't imagine so much oil coming from them. I also used Ultra Black RTV instead of the FIPG WSA111 suggested.
It wasn't a success, it actually got worse. I was now using about a quart to do the 20 mile round-trip to and from work. I ran about town for a month like this, and got tired of leaving oil trails everywhere I go.
The second time, I got FIPG, and another Fel-Pro two piece seal from AutoZone. Didn't try adding sealant to the threads this time around either.
Now oil is just FLOWING from the bell-housing of the transmission.
YouTube link: http://www.youtube.com/watch?v=3Dwly4vbyzE

How can I fail so horribly? Could there possibly be something else wrong? The engine does need a rebuild, but I'm too poor to get that done right now. I was thinking of a 302 swap from a junkyard 'stang over the summer. I just need to get this leak dealt with until then. I'm going to try again this weekend, but I figger I'd ask the collective knowledge here for any sort of insight. Thanks, and sorry for the length of this post.

 

[Ronbo]

I don't know that the bolts will leak that bad however, when they were new they were painted with the sealant. Every time you put them in and take them out more and more of the residue sealant will disappear. as bad as your leaking though....as you indicated, I dont think its just the bolts either. If there was a burr or something on the crank, it would tear the craap out of the seal in short order.

 

[Ronbo]

Oh shEEEET no! I just watched the video. Are they giving you the right flipping seal? The thing should wrap around the crank like a glove. That leak there indicates the you have a hole somewhere. Sorry guy, I get easily excited these days :roll: When I did my engine, the seal was part of a Felpro rebuild kit. Are you dropping the tranny when you do this? You need to get a visual on the seal before you button it up. If you are trying to do it with the tranny in the car you really can't tell if the seal ends are butting up to each other good and tight. Make sure the caps are sufficiently loose so that the seal can slide in there without bunching up. As you have found out, there are many things that can cause this to fail. Someone with FAR more experience will be along shortly to help you out. I feel you frustration, trust me. Good luck buddy!


Ron

 

[MustangSix]

Another possibility is that the oil passage to the lifter galley is open.

 

[fairmontwagon]

I'm sure it's the right seal. I got the seal from a Felpro full gasket set. I was going to replace every seal, including the head gasket, just for fun and a learning process. I got lazy though and just did the rear main seal. It seems that I'm going to pull the engine to get this rear main seal done, I wanna get a very good visual on the seal. I can also change out the other seals and gaskets.
Where and what is the lifter galley?

 

[Ronbo]

Looking at the rear of the engine it will be left and up from the crank. I can't remember if the plug is driven or threaded in on that one. How bad does it leak when it is not running? Because as bad as that puppy is leaking chances are something popped out like Jack suggested. If you can see in there, you should be able to tell where its coming from.

Ron

 

[Falcon Ranch]

with that kind of serious problem, I would just plan a weekend and pull the motor so you can get a up close and personal look...motor can be pulled in a couple of hours easily with friends...fix the problem and maybe a few other leaks as well...I'd hate to be your driveway