97 xk8 coupe, 69k, dropped the trans pan today, drained fluid, removed old filter and replaced, put in trans go pressure regulator valve, washed and sanded and painted the pan, new pan gasket, wire wheeled every pan bolt, put it all back together and wouldn’t you know I go to take out the fill plug and it backs out and hits the exhaust and can’t come all the way out! Wtf!!

im currently trying to loosen up the exhaust to pry it over enough to get the fill plug out. Any thoughts or suggestions? Anyone else run into this issue? I know my exhaust has been messed with due to visible welds, and aftermarket hangers, maybe that’s why, not sure.

 

The factory exhaust is slightly lower than the fill plug.

 

Bummer. Yes, somebody has messed with your exhaust. As stated, the exhaust should be slightly lower than the fill plug, although clearance is still tight. And great fun to work around when the exhaust is hot. All you can to is loosen everything and try to pry it far enough away to get the fill plug out. Putting it in again will be a pleasure, too, I'll bet.

 

Your exhaust has obviously been misaligned as there should be plenty of clearance to remove the fill/level plug above the exhaust pipe. You need to loosen a few bolts and drop the exhaust a little.

As a learning point, one should always check that the fill/level plug can be removed as the very first action when working on any car components which have such a plug.

Richard

 

Problem solved, turns out I was after the wrong bolt thinking it was the fill plug. Found the correct fill plug and was able to get the plug out, pump in almost four quarts of zf oil, started it and got about another 2 quarts in. I measured what came out and it was about 5.5-6 quarts. Went for a ride and it was shifting better than before, so I’m happy. Gonna grab some more oil and give it a couple hundred miles and drain through drain plug, and fill it up again. I’ll attach a picture of the full plug for anyone who’s curious, and to be clear it is on the passenger side(lhd) in the back of the trans. The bolt I was originally trying to take out was on the drivers side(lhd) in the front of the trans, a 19mm hex bolt. This was wrong and a mistake by me but that’s what happens when you stay up for two days and drink heavily and try to repair something, lesson learned the hard way but a good story nonetheless, lol