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1st off just spent the last couple of days (and nights) with Clay @ riffraff, great guy and is able to get almost anything for our trucks. While installing the transmission temp sending unit the bolt on the drivers side "test" port will not budge. I have tried everything I can think of and started drilling it out. Then since I was 4hrs from home I stopped drove home and now have to decide what path to follow. Is there another location for the sending unit? If I remove the pan will I see the plug at the recommended spot? If I cannot see it I have decided I would rather not drill it out and run the risk of metal in the tranny. Instead, I was wondering about dropping the pan and drilling and tapping a location on the pan. Any recommendations on placement, I wll add the pan is a 14qt hughes. Any suggestions would be great. Thanks in advance.
Usually those bolts are not that tight. You should be able to feel the back of the plug with the pan removed, don't know if you can see it without a mirror. Maybe Mark K will see this and let us know about alternative locations that will work.
Try soaking it with PB Blaster it will weep into the threads. You may have to hit it a few times over the course of a few days. Another method is to apply a little heat from a propane torch around the plug. This will cause it to expand and hopefully break the corrosion free. Do this very carefully though. Do not use to much heat or an Oxy torch. Propane or Map gas only.
You should be able to feel the back of the plug with the pan removed, don't know if you can see it without a mirror.
No, you can't get to the plug with the pan off. It isn't a pass through into the pan, it's a tap into a pressure line. If it were open into the pan it wouldn';t be able to hold pressure.
Be VERY careful using heat near an aluminum case. It doesn't take that much heat to ruin the case, and that's expensive!
If you can't get it loose with penetrating oil, you should look into installing it in the pan.
We soaked with penetrating oil, used some heat, not a lot due to the aluminum, dremelled a slot and tried to use a screwdeiver after the head rounded using a 6sided socket, drilled the center and tried an ez out. Will not budge. It was suggested to jb weld the center back into the bolt, and drill and tap the pan. Where on the pan would be the best location?