I'm helping a buddy replace the rear main on his 1971 Bronco 302. We have tried 3 times, and each time... the thing pukes oil. Like... it _pours_ out. We are doing this by dropping the oil pan, and removing the rear main bearing cap.

Last time we installed the seal, we triple checked that it was facing the correct way, we spun the crank and checked the surface, we lubed the seal, then had someone turn the crank while we fed it upward. we left the seal just barely "clocked" over, so the break in the seal is not aligned with the mating surface of the bearing cap and block. we also dapped some RTV on the ends of the two piece seal, where it would mate to its other half.

when the engine is running, the rear main is leaking and the clutch dust cover catches most of the oil. when the engine is shut off, oil pours out of the dust cover. in a 10 minute drive, it motor might lose 1.5-2 quarts.

motor looks like it was recently rebuilt.

any thoughts out there?

I am not much of a Ford man but sounds to me like you may have the a oil gallery plug leaking.. their should be 2 or 3 plugs around the plug at the rear of the cam.. To get to these you will need to remove the tranny .. Another thing to check would be the oil pressure sending unit if it is at the back of the block(like I said I am not a Ford man so I do not know hwere the oil pressure unit is)..

oil galley plugs: great idea. tranny is coming out soon. we shall see.

any other hypothesis out there?