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Discussion Starter #1
Had a small oil leak where the oil pan meets the bell housing on my 89 Sahara. Dropped the oil pan and replaced the rear main seal thinking this would solve the problem. After getting the oil pan back up with a brand new gasket on it and starting it up, it starts leaking severely. After looking I realized the gasket had broken in that same spot near the bell housing. Thinking I may have broke the gasket when tightening the oil pan bolts, I dropped it again, put a new gasket and cranked it again. This time I stayed under while it was idling and watched the gasket through the small gap between oil pan and bell housing as it broke. Something caused it to rotate(from driver side to passenger side) and pop causing oil to leak quickly out. I'm using the single piece Felpro gasket. Does anyone have any idea what could be causing that gasket to break or if I missed something?
 

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The oil pan gasket is breaking, not the rear main seal. Is that correct? Could the crankshaft be rotating and contacting the gasket? Pan gaskets should be installed with no sealer. Sealer causes the gasket to spread, and not compress. Felpro offers a cork gasket and the permadry gasket. I would go for the permadry.
 

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Discussion Starter #3
Yeah it was the gasket. Switching to the four piece cork gasket after learning that advanced autos website was incorrect in recommending the one piece I was using. Reviews on the one piece said the same problem I had. Installing tonight. Hopefully this will fix it.
 
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