My mechanic says that the only way he can replace the oil pan on my Excursion (Diesel) is to remove the engine. Is this true?

Here's a link on replacing your oil pump,it says to remove timing belt which means I will send a link on that too,k. Repair Guides Engine Mechanical Components Oil Pump AutoZone com Here's the second link on removing your timing belt,best to put a new belt on too. Repair Guides Engine Mechanical Components Timing Belt Sprockets AutoZone... Here's a 3rd link on removing timing belt cover. http://www.autozone.com/repairinfo/repairguide/repairGuideContent.jsp?pageId=0996b43f8037a037 Here's how to remove rear cover. Repair Guides Engine Mechanical Components Timing Belt Rear Cover AutoZone... Here's how to remove oil pan. Repair Guides Engine Mechanical Components Oil Pan AutoZone com

Here's a guess, I've only done a few.
Removing the pulley to change the seal would probably require removing the engine, because after you remove the bolt holding it on, you need to use a "pulley puller" to get it off.
I think there is an easier way.
I think mechanics drop the oil pan and change the gasket without removing the pulley.
Maybe you could call around and find if this is true.
Pulling the pan might not require removing the engine.
Be blessed.

Blower Motor
See pics bellow Removal

1. Disconnect the electrical connector from the vacuum pump (7.3L diesel engine).

1. Remove the bolts (7.3L diesel engine).

1. Disconnect the vacuum hose and remove the vacuum pump and mounting bracket (7.3L diesel engine).

1. Disconnect the speed control servo connector (5.4L and 6.8L gasoline engines).

1. Remove the bolts and remove the speed control servo (5.4L and 6.8L gasoline engines).

1. Disconnect the connector.

1. Remove the blower motor ventilation tube.

1. CAUTION: Carefully remove the blower motor so as not to damage the wheel.
   Remove the screws and remove the blower motor.

1. CAUTION: If the wheel is to be reused, clean the corrosion from the shaft end prior to removing the wheel.
   Remove the wheel from the blower motor.
   1. Remove the push clip.
   1. Remove the wheel from the blower motor

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Installation

1. Follow the removal procedure in reverse order.

depends on whether you have 2WD or 4WD. The manual says if you have 2WD you have to remove the tranny,but not if you have 4WD. See procedures below.

5.9L & 6.7L Diesel Engines
2WD Models

1. Before servicing the vehicle, refer to the Precautions Section.
2. Open the hood.
3. Remove the negative battery cables.
4. Raise and support the vehicle.
5. Remove the transmission oil cooler lines.
6. Remove the propeller shaft.
7. Remove the starter bolts.
8. Support the starter.
9. Remove the torque converter bolts.
10. Remove the exhaust hanger bolts.
11. Remove the gear shift cable.
12. Remove the wiring harness.
13. Remove the transmission mount.
14. Remove the crossover bolts.
15. Position the transmission jack.
16. Remove the bell housing bolts.
17. Remove the transmission.
18. Remove the flywheel housing bolts (8).
19. Remove the flex plate bolts (8).
20. Remove the engine oil dip stick.
21. Drain the oil.
22. Remove the steering rack bolts.
23. Remove the oil pan bolts.
24. Remove the oil pickup bolts.
25. Remove the oil pan.

4WD Models

1. Before servicing the vehicle, refer to the Precautions Section.
2. Open the hood.
3. Disconnect the battery negative cables.
4. Remove the intake air assembly.
5. Remove the radiator shroud retaining bolts.
6. Install engine support fixture No. 8534B.
7. Raise and support the vehicle.
8. Drain the engine oil.
9. Loosen the front engine mount bolts.
10. Lower the vehicle.
11. Use the engine support fixture No. 8534B to raise engine out of the front mounts.
12. Remove the engine oil dipstick.
13. Raise and support the vehicle.
14. Remove oil pan bolts, break the pan to block seal, and lower pan slightly and remove oil suction tube fasteners.
15. Remove oil pan and suction tube.
16. Remove the 2 bolts from the front of the engine block stiffener.
17. Remove the oil pan.
    

FORD 2.0 MAZDA DIESEL ENGINE.YOU REMOVE CRANKCASE.FIRST DISCONNECT NEGATIVE BATTERY CABLE.RAISE AND SAFELY SUPPORT VECHICLE ON JACK STANDS.DRAIN THE ENGINE OIL.REMOVE THE BOLTS THAT ATTACH THE OIL PAN TO THE ENGINE AND REMOVE THE OIL PAN.CLEAN ALL GASKET MOUNTING SURFACE.APPLY A 1/8 INCH BEAD OF SILICONE SEALER ON THE OIL PAN MOUNTING SURFACE.INSTALL THE OIL PAN AND TIGHTEN THE BOLTS TO 5 - 7 FT LBS.

If it is in fact the oil pan gasket that is leaking, then you would first need to drain out the oil through the oil drain plug and recycle the oil. Then you can remove the oil pan and replace the old gasket with a new one, refill with the proper amount of oil. Then you can run the car and see if it still leaks.

first drain the oil then u need to remove the bolts that fastened the oil pan to the crankcase using a sockrt wrench / clean it with gasoline/ dry it/ put a new gasket or gasket sealant would do tighten it evenly and fill the engine with fresh oil.

for the 5.4 gas engine, no, for the 7.3 diesel, no

sadly I don't think there is. The oil pan is huge and sections of the frame are in the way of getting it in and out without damaging the pan severly. pulling that massive engine and replacing the pan, then putting the engine back in and reconnecting everything in 14 hours is a good estimate. sorry for the bad news

a 7.3 with 97K miles is just getting started on it's lifespan. These motors will last for sometimes 300K miles with regular service. They do have a 100K powertrain warranty so you're close to out of warranty on this one. The transmissions and torque converters were sometimes weak, but if you treat them right, they'll last.
Personally, I've got a ;'01 Limited since 2003 and I've got close to 180,000 miles on it... I've done regular service on it, brakes, changed the tranny out, have a banks kit on it, and it runs like there's no tomorrow.
Great rig, highly recommend a diesel.
Even tho ford isn't making the Excursion any more, the Super Duty is around to stay for a while so there'll always be service parts for the Excursion...
Hope that helps in your decision... KEN