Many times the OEM oil pan bolts and washers bend the pan inward around the pan holes when overtorqued and when too much RTV is used, especially when too much RTV is used and someone attempts to tighten the pan down more after the gasket has cured.
Clean your lower and upper pan thoroughly with a razor blade, do not gouge the surfaces, you may want to use some brake cleaner to assist.
Check the surface of the holes on the lower plan, if they are not at least flush, hold the edge of the pan against a table edge and find a small block of wood, to fit the contour of the edge of the pan. Pound the holes in the pan until they are flat with the rest of the surface.
Add new rtv, and it should seal just fine. I also added slightly wider washers to the lower oil pan bolts so that way the outside inner edge of the pan holes don't warp/stretch again. Never had a problem with my lower pan leaking again.
Last edited by ferrari21
on 2013-10-11
at 21-59-18.