I've wanted to do this for years, but just never got around to it.... Should make dropping the pan and changing the filter in my garage a lot less messy! I've just taken the truck in to a shop to have the trans service done in the past.... Extra $$$$, but convenient at the time...

I first drilled a 1/4" pilot hole while it was full to let it drain into a pan. A little messy still, but still not as bad as trying to drop a full pan of fluid

Pulled the pan and then drilled a 1/2" hole. Filed the perimeter inside and out smooth so I'd get a good seal on both ends. Inside is a 'plastic' washer and on the outside is a 1/2" O ring that expanded when the nut was tightened on the inside of the pan. The plug has an O ring on it as well, and might need to be replaced after each use, but little 3/8" O rings are pretty cheap..

It takes 6.5 qts of trans fluid to fill back to the middle of the 'hot' mark on the stick when the fluid IS HOT by just dropping the pan..

FYI, if you check the level when 'cold', make sure you only fill to that COLD mark on the stick... It's accurate, as that's what I did my initial fill to after doing a quick measure of the drained fluid amount and I had estimated that at 6 qts... When I checked the 'cold' level, another 1/2 qt put it at that level. When I checked the 'hot' level, it was then right in the middle to the 'full hot' mark.. Another 1/2 qt will make it "FULL", but IMO, it's better to be just a tad less then 'full' then to risk overfilling...

Mitch

 

Here's mine.I welded a 1/4" thread-o-let onto a factory pan and use a brass plug to seal it!
http://i206.photobucket.com/albums/b...r/PICT0081.jpg
http://i206.photobucket.com/albums/b...r/PICT0080.jpg

 

I can appreciate that Blue... But, I don't have a welder and haven't welded anything since HS, so until I build the 5,000 sq ft shop of my dreams, I ain't getting a welding setup!

I did think about having it welded up however... But, it was a matter of time and since it was on a Sunday afternoon that I did this, I wasn't going to leave the 'warm' confines of my little 2 car garage, with the "Mr Heater" running, keeping the garage at a nice, 'warm' 65* (it IS Winter in the NW!), an NFL playoff game on the 20" flat screen TV in the garage and lots of beer in the garage fridge, not to mention, the wife out with a girl friend to watch a movie (I think she said they watched 'Seven Pounds'?? Whatever.... )

Oh, life is good, and working on your own truck, with your own tools and in the comfort of a covered space is all that a man needs!

Mitch

 

Nice job!

Damn Mitch , that would make for a good Beer commercial - perfect setting.

BTW - My E40D pan came with a plug - So did the converter. They didn't in 97 I take it. ?

 

I've got the drain plug on the converter, but not the pan.. I've heard that some E4OD pans had the drain plugs on them... Mine was a 3/97 build, so who knows??

Regardless, I've got one now, so it's all good!

Mitch

 

I have pics of it in my old Gallery that I would post, but the galleries are down. Also get 9 quarts from the pan / IF I pull the filter . - I have pics of that too

Build date = 7/98

E4OD/4R100w

 

I'm a pipefitter/welder by trade.I run a fab shop so I get to play a little on the side.

 

Mitch, good job. They should come from factory with one.

What brand plug is that? Did you use a stop on the initial bit?

 

hey jward, It is just a 'generic' 1/2" threaded plug that I picked up from an auto parts store where they have other replacement oil pan plugs and such (I've already tossed the packaging...). Cost about $5 if I recall. I did have to buy a separate 'nut' for the inside of the pan and the guy thru in the 1/2" rubber O ring for free..

I did use a small section of some clear 3/8" hose I had laying around on the bit of the drill for my initial drill thru, so that it would only go in about 1/4". All that's there in that reservoir in the pan is the pickup pipe to the filter. The bolt clears the pickup pipe on the inside, as I felt no interference when I put the pan back on.. Oh, remember to put the cleaned magnet back in the pan before bolting it all back up! I got to enjoy my tools and garage setting a little longer and have it down real good on removing and replacing the pan! ha, ha!!

On my next engine oil change, I'll probably drain the pan and refill with some more fresh stuff.. The 'old' fluid is still pretty 'clear', so I think a couple of fresh pan refills will be fine.. I did have the TC drained just after I got the truck, and have maintained a yearly trans service from then on... Now, I'll probably just drain the pan every other engine oil fill and then do a filter change every 30k miles....

193,000 miles on the original trans and it's still tight and clean. The magnet barely had any residue on it... I just use the off the shelf 'dino' fluid from Wallmart that comes in the gallon jugs... Super Tech or somehing like that.. I think a gallon was only $10?? It's listed as DexIII/Mercon.. Perfect for my E4OD..

Mitch

 

Just wanted to update this post with the additional info to NOT USE A RUBBER "O" RING to seal with!!

While it never leaked a drop for the last 4 months, I took it out on a camping trip this weekend and got the trans temp up to 180* and on the trip home, noticed that it was dripping at one of our stops! I broke out the tools and tried to tighten it up, but it just spun on itself and the "O" ring was coming apart... I actually made it worse by trying to tighten it, but I was still 75 miles from home so I got some extra fluid, topped it off and headed home... Well, I made it fine, but the underside of my truck is now rust proofed for a little while!

I fixed the leak by pulling the pan and re-doing the bolt with a full size metal washer on the inside and the original nylon washer on the outside.... Tested the seal and it didn't leak on the bench with fluid in the pan after an hour, so I installed it in the truck and filled it back up and took it for a spin and so far so good... No leaks... But, it didn't leak until it was worked hard, but I'm sure that was due to the "O" ring failing when it got heated up.... (again, it's the first time it's been over 150* since I did the plug...)

Time will tell... Going to tow the trailer again next month, so will wait and see!

Mitch

 

Thanks for the update. Sorry to hear about your leak. Glad you got it under control.

 

I ended up taking mine back apart (4R70W) for leakage, as well. I slathered mine up with UltraBlue RTV on the inside when I reassembled it, and use the plastic washer on the outside as you did. No leaks now.

Andy

 

Check that. Was just under the truck tonight scoping out where to install my temp sensoir, and saw some seepage. Apparently my rebuilder broke it loose when removing or tightening the plug. Guess I'll pull the pan it and re-seal/replace it. (I can't really blame him for something I added.) Maybe I'll just have it welded this time?

Andy

 

I don't know about using the RTV on the inside?? Too much risk of it coming loose and then it's in your pan.. I'm sure the filter will keep it from getting inside the trans, but why chance it? It either seals with a washer, or you weld it up...

I pulled mine again this weekend, as I found a 'proper' drain plug that had the correct nut and washers for it. I added a lock washer on the inside to hopefully hold the bolt in place this time!

So far so good... But, that's what it's been like the other two times too!

Mitch

 

The Ultra-Blue holds pretty tight, but I see your point, Mitch.

I may just replace the entire thing. Where did you get this "proper" drain plug?

Andy