I'm in the process of replacing my flywheel and clutch and, while doing so, I planned on replacing the rear main seal. I (stupidly) assumed that it would be a simple issue of taking the old seal off and putting old one on. Um, yeah........

After reviewing the FSM, I see that taking off the aluminum oil pan will require me to remove a fairly large number of components and, consequently, will likely take hours of work by itself. I'm comfortable with removing all the engine mounted components but, the Y-pipe is the original component and, the bolts are so rusty that I don't think I'd even be able to get them out. For those of you who have done a RMS before, do you think it would be possible to drop the aluminum oil pan without taking the Y-pipe off?

 

i don't believe so IIRC the upper pan is what retains the seal in place and if you need to lower just an inch to get it out how are you gonna clean the surface and reapply the RTV to seal it back up

 

In short, no. Spray the pipe with PB Blaster, let it soak for 15 minutes, clean, and repeat. You're going to need to drop the pan enough to clear the crank. Even if you did somehow get it off, you would be in a horrible way when you tried to reinstall it. My advice: give yourself plenty of time. You'll have to repeat the job if you rush it.

EDIT: Don't forget the two small orings in the pan and the oil cooler oring.

 

Hmmm, well, it seems as though the seal is leaking just a bit but, not enough to cause serious worry. I think I'll put the car back together and get at this seal in the spring.