Private Snuffy just about got me..... BIG TIME!!!

[RRaulston]

So in my bid to complete the fluid change on all components, the transmission was next. I crawl under and drain the transfer case. Got a few gallons of 15w 40 which was dark but not burnt. It was old. I then make my way to the trans pan and reach up and touch the plug and it wobbles. Confused, I first try to tighten it to verify it was loose and it won't tighten. IT WON'T FREAKING TIGHTEN! So, I remove it, and, in the pic, you can see what I found. A transfer case drain plug. I have to be the luckiest guy ever in that the plug didn't fall out and ruin the trans... The other pic shows the threads in the pan. I think there are enough threads left to be safe with the correct plug. Weird, but I'm so pissed and thankful at the same time.... Does anyone have an Allison part number for the pan plug? No kidding, I'm touching everything on this truck before I venture out more than 10 miles. (my insurance tow limit) Thanks!!

 

[RRaulston]

Well, after checking with Allison, that might be the right plug. They have nothing longer.... $2400 for a replacement pan...

 

[swbradley1]

Ouch

 

[Wingnut13]

It would be a pretty easy part to machine from scratch or from a correctly sized bolt. That way you could engage those five threads you have left.

Other option would be to pull the pan, weld it back up and then drill/tap your drain hole again.

All sorts of options before you spend a couple kilobucks on a new pan.

 

[Suprman]

I have a pan here

 

[GeneralDisorder]

There are drain plug specific thread repair kits. No need to even pull it off.

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www.timesert.com

 

[MrMikey4026]

What you are calling the pan is really the valve module. The pan is not separate and is not a lot of fun to remove and replace. If you have watched the video on Helicools Helipad on YouTube of his transmission service , you will see that his drain plug is just a fine threaded bolt with a copper washer on it. That is the way that I would manage the problem. You would probably have to run a tap with grease on it to clean up the damaged part of the threads. The grease will collect the chips. The plug can be seen at about four minutes and again at eight minutes.
Cheers.

 

[RRaulston]

There are drain plug specific thread repair kits. No need to even pull it off.

+ TIME-SERT® STRIPPED OIL DRAIN PAN REPAIR KITS FOR STRIPPED THREADS + Stripped oil pan thread repair kits, leaking oil drain pan stripped or leaking threads stripped oil pan oil drain pan stripped threads stripped drain pan threads, leaking oil pan threads leaking, fix stripped oil drain pan leaking drain plug threads

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www.timesert.com

View attachment 886011View attachment 886012View attachment 886013 What you are calling the pan is really the valve module. The pan is not separate and is not a lot of fun to remove and replace. If you have watched the video on Helicools Helipad on YouTube of his transmission service , you will see that his drain plug is just a fine threaded bolt with a copper washer on it. That is the way that I would manage the problem. You would probably have to run a tap with grease on it to clean up the damaged part of the threads. The grease will collect the chips. The plug can be seen at about four minutes and again at eight minutes.
Cheers.

I had no idea it was that complicated. So, I fixed it today. The plug is a 3/4-16 thread. I bought a 2" bolt and cut the threads down 1/4". I then used my band saw and cut half the thickness of the head off. It will clear the exhaust without interference now. Since I had several threads deep in the hole that were good, it threaded in with no issues. We are good now. I will time-sert it someday, but the 3/4-16 kit was over $300 and, well, its xmas and have to keep the family happy.. Thanks for all your great suggestions!!

 

[Green Mountain Boys]

Looks like Pvt Snuffy worked on my truck also.

 

[87cr250r]

For those looking to repair, I don't think Timesert has the correct kit for this application. Full-Torque has an insert with the counterbore for the o-rings.

O-Ring Boss Inserts for Hydraulic Fittings and Drain Plugs - Basic Kits On Lock-N-Stitch

Browse O-Ring Boss Inserts for Hydraulic Fittings and Drain Plugs - Basic Kits in the Lock-N-Stitch catalog including Order #,Internal Thread Size,Shoulder Diameter,A,B,Tap,Inserts (Package of 5),Install Tool,Drill Bit,Size

castingrepair.locknstitch.com