Transmission Pan Headache
 

Today I felt industrious so I decided to change the transmission fluid and filter in my 94 S-10 Blazer. I had ordered a drain plug for the pan so that when I removed it I could install the drain plug and not have to drop the pan for routine fluid changes.

I knew going in that I had to remove the cross member to get the pan out. I took it out and jacked up the end of the transmission to give some extra clearance for the pan. Even with that I had an extremely difficult time getting the pan off the bottom of the transmission. I pulled the filter out of the housing and was able to get the pan out with the filter free.

I drilled the hole in the pan for the plug and installed it. When I went to reinstall the pan I spent two hours fighting to get the front of it to clear the exhaust crossover pipe. To get it in I had to take the exhaust pipe off the manifold on each side and drop it down a couple inches. That was an unpleasant process. I also had to put the filter in the pan and then press it up into place with the pan resting on the crossover pipe.

When I finally got the filter and pan in place and started installing the bolts I realized that the plug was too tall inside the pan and it hit the underside of the valve body so the pan won't seat against the underside of the transmission. Aargh.

Now what? I'm not a welder but I really wish I could just weld a nut to the underside of the pan where the hole is. That would be the best solution to me if I were capable of it. Other than that I'm considering making a patch for the hole and securing it with J-B Weld or just finding another 4L60E/700-R4 pan and slapping it on there.

I'd appreciate your input.

find another pan, too risky to depend on a patch job for it... no fluid=cooked trans

is there any way to trim the inside part of the plug? i have never seen one so i wouldnt exactly know. just a thought tho. but if you cant get the plug to fit then i would do like what you and coolasice said and get a new pan. they are probably pretty cheep at your local junk yard if you have one.

I decided to take your advice and chase down a new pan. I'm fortunate to be surrounded by pretty good junk yards. I've the new pan and I'm headed out to the shop to put it in. I have to do it by 4 o'clock because I have a gig tonight and I have to wear a tuxedo.

Thanks for the help!