Hello. My 2005 Accent has a busted flex pipe (flexible section has cracks) and the oil pan is leaking oil from a rust spot at the bottom! You have to disconnect/replace the flex pipe in order to reach and remove two of the oil pan bolts located directly above it. Bad design. Bought a new oil pan at Canadian Tire; about $22 cheaper than the local Hyundai dealer, but, still too expensive. Had to cut out the rusted bolts holding the flex pipe and will have to drill new holes into the flange to insert the new bolts. Removed all the pan bolts. I'm having a very difficult time trying to remove the old pan. The original sealer just doesn't let go! I'm trying to pry off the old pan with a chisel but there is very little space to use a hammer on the chisel! Any ideas? Thanks.

 

I may have already replied to this on a different thread, but if it wasn't yours then here's what I suggest. Use a sharp box cutter instead of chisels or wedges - dry RTV is easy to cut but really hard to pull apart. When you get the pan loose, make sure that you clean off all the old sealant and then degrease both surfaces before applying new RTV (I use Red, but the pan doesn't get too hot so even Black should work) to both surfaces. Don't use more than 1/16" (thin coat) on each surface, it'll just squeeze out when you tighten the pan to the block. When you're installing the new pan, pull the bolts snug, not tight, and let the sealant set overnight, then tighten the bolts to the specified torque, but be careful not to overtorque them - the early Hyundai's have a really poor quality fastening system and the bolts/threaded holes are easy to screw up. Once the pan is tight, you can add oil and you're good to go.