Hi y'all,
I need help with my Disco. Recently, I tackled the dreaded head gasket job (please hold the applause), but now I'm facing a crazy leak at the bottom of the front cover/oil pan area. Initially, I suspected the crankshaft seal, so I replaced it with a spare one I had. This seemed to help a bit, but as the engine got hot, the leak came back.

Upon investigation, I discovered that the middle threaded stud under the front cover is stripped (yes, I was using a torque wrench set to 16 ft-lbs). It seems there's not a great seal because of this. I'm just kinda stumped because it was a new front cover...

Does anyone have any advice, or am I stuck buying a new front cover?

 

Is the hole in the cover stripped, or the threads on the stud stripped? If the former is the case you can helicoil or even tap it out to a larger size, if it is the latter you can replace the stud with a bolt or another stud. have you done the pcv mod? The oil pan is very stiff structurally and it seems unlikely that one loose fastener would cause it to leak if the crancase is not pressurized (pcv make sure it is not)

 

Thanks for the quick reply, it's the hole in the front cover. I'll look into the options you sent. I also have not done the PCV mod but recently heard about it. That will probably be the next thing I do.