I just recently changed the driver side valve cover gasket due to a leak. The old gasket was a felpro gasket that looked fine. I installed a new felpro gasket and still having a leak. Noticed the leak is actually coming out of each bolt/stud head and that's where the old one was coming out. Are these bolts and studs supposed to have some type of rubber washer? All it has is a metal washer. I've tried looking for parts online and oem bolts for my year seems like a unicorn to find.

 

Are they torqued to spec? Maybe they are cracked internally causing the oil to enter into the bolt cavity. Might be time for a new driver side valve cover.

I'd remove it and examine the area around the holes that are leaking with a magnifying glass to see if there are any cracks.

 

Yes torqued to spec except for 2 I couldn't get torque wrench to. The valve cover is in mint condition. The bolts on the bottom side of the cover (in line with the spark plugs) are all seeping oil from the bolts. Exact same leak it had before I changed the gasket. Do you know if the bolts are supposed to have a rubber washer too?

 

Is this the original engine (5.2L or 5.9L). If so, I'm pretty sure those are just seal, valve cover and bolts with no other seals.

Maybe try putting a thin layer of RTV on each side of the gasket around the bolt holes and see if that stops it. If not, oil must be getting through elsewhere such as through the threaded area of the heads.

If you put the covers on a flat surface and shine light through the gap, does it look perfectly flat? I've seen them leak after being severely over tightened causing the metal to bend at the bolts. Same with oil pans and transmission pans.

 

It's the original 5.9. I'm the second owner and had it for over 3 years. There was always a very slight seeping at the valve cover but on the top side near the bolts (not at the gasket). I finally decided to replace the gasket a couple of weeks ago. The blue felpro gasket I removed looked fine and my new one looked identical. I cleaned the cover really good and to the eye it looked mint. I didnt compare to shining a light. I may try the rtv. I did notice the felpro gasket rubber portion around the bolt holes were pretty minimal. I'm thinking it's coming through that portion. Might try a different brand gasket.

 

Is the crankcase building pressure? If so the pressure will push oil out where it can.

 

Not sure. that's beyond my knowledge. I've replaced the pcv to oem and seems to work fine. I have a stethoscope and can hear pretty good vacuum sound coming from the pcv hose so I'm presuming the pressure is being released.