A Few BH ZZ4 Repair Questions

[The Mindless Philosopher]

I'm finally preparing to get off my duff and start another round of repairs (about a half dozen) to get my 2001 Boss Hoss ZZ4 trike road worthy again before the heat returns. Before I dive into those repairs, I have three questions concerning the oil pan:

1. Can I drop the oil pan to replace the leaking forward main seal by removing the exhaust headers to free up room instead of having to deal with splitting the frame?

2. If so, what are the best replacement header seals I can get for the D-port (L94, I think) 5.7L heads?

3. Any suggestions for removing the header bolts without twisting the heads off of them? Are they likely to cooperate? Should I soak them in Liquid Wrench before attempting to remove them?

Thank you.

[The Mindless Philosopher]

I guess I'll dig in and figure it out.

[Imzz4]

The crossover bar won’t allow the pan to clear enough to get it out.
A great penetrating fluid I use is Kroil . Some heat will also help .

[knockdolian]

People on this forum have managed to cut out the cross member and weld on flanges so to remove easily next time. Heat will definitely be the way to go to remove the manifolds. Good luck with it .

[Orlando606VetteTrike]

You sure it's not the harmonic balancer seal?

[The Mindless Philosopher]

You sure it's not the harmonic balancer seal?

I don't know for certain. I haven't gotten around to it yet, but the leak is most definitely coming from the front of the block. I've had a corresponding coolant leak that I thought was from the radiator. It looks like both might be coming from the same location. If that's the case, is that a tough repair?

[The Mindless Philosopher]

I'm watching different YouTube videos to try to get an idea.

[The Mindless Philosopher]

Doing some more digging, it looks like if my timing chain cover/harmonic balancer seal is the problem (or one of several problems), the cover is a one-time use item, so I'd have to replace it. The Dorman 635-505 looks like it's the correct replacement.

https://www.summitracing.com/parts/rnb-635-505

[Orlando606VetteTrike]

Make sure to remove the 2 front oil pan screws to release some pressure of the front cover. it'll help when sliding in the new cover. Also, only use the Right Stuff sealant when putting back together. Clean thoroughly and put back together. In addition, i'd replace the 2 orings that are used on the water manifold. As old as your trike is and the constant barrage of issues you seem to have, change them. Call a dealer or match them up locally at hyd shop. Check the hose from the water pump to the manifold too.

[Paul H]

And don't over use
the sealent...

Paul H

[Imzz4]

"Right Stuff "is very good. I use it too after brake cleen or acetone on the pieces.

[The Mindless Philosopher]

Thank you all for the replies. I still haven't dug in. A steady stream of medical problems and now this COVID-19 mess has gotten in the way. The trike is on jack stands for now.