The drain plug on my oil pan has been leaking slowly for some time now. After inspection, I found that someone in the past installed a self-threading oil plug into the aluminum pan. I'm assuming the original plug was over-tightened. After several tries using metal washers, fiber washers, copper crush washers and a combination of all of them I've never been able to get it sealed properly. Soooo ... I broke down and bought a new oil pan. I'm sure it's going to solve the problem but it's so pretty I hate to install it! For those who have replaced a pan, is gasket sealant necessary?

 

on all my 2nd gen cooper, I used sealant. i used a gasket by itself once and it was leaking. if you use sealant, make sure you give it enough time to cure before adding oil. I usually let it set overnight.

 

And, install a Fumoto drain valve.

 

It's an MC40 so it has a drain plug connected to the oil temp gauge but I love the idea of a Fumoto.

 

Looks nice, yep on the Mc40 if you want keep it factory you have to keep that oil drain plug/sensor. I guess you could tap a new hole next to it and keep the sensor there and then have fumoto on the main plug part?

 

When I pulled the pan there was no sealant from the factory so I reinstalled it that way. Solved my oil leak - yay! By the way, swapping the oil pan is WAY harder than it needs to be because there are so many things attached to it, i.e., alternator, transmission, engine mount, etc.

 

You should try tapping the hole oversized first. You can buy various kits and drain plugs to try this.

Worst case, you can tap it to use a pipe plug.

 

I was about to say the same thing,
but held my tongue (finger) as I saw
the OP already bought an oil pan.

 

You can always return an oil pan...

There's also an option of welding on a new bung / fitting - very common in the trucking industry.

I repaired the steering box on our motorhome that way. Saved lots of $$.

 

I didn't replace my oil pan, just changed the gasket, didn't use any sealant, no leaks. You should be good.