DON'T DO IT! - Powerboost Transmission Pan Removal

[Ajzride]

I can't get the transmission pan off past the exhaust. This video from ford shows the pan slide right out, but mine will not clear the exhaust.

https://www.fordservicecontent.com/Ford_Content/videos/WorkShopManual/V27.mp4z

At this point I've remove the transmission cross member and transmission mount (the exhaust attaches to it), and disconnected the exhaust behind the Y-pipe, but the exhaust is so stiff from the turbo back that it still has no flex and I cannot get enough space to get the transmission pan off. Surely I don't need to disconnect the exhuast at the turbos just to change the transmission filter?




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EDIT: Now that it is back together I'll list out all the steps. They are listed chronologically in how I did them, with the number to the left listing the advised order


9) Remove the transmission pan heat shield using 10mm socket
10) Remove the transmission pan bolts using 8mm socket
11) Remove the 6 studs for the heat shield using 13mm socket
4) Remove the nuts from the transmission to cross member bolts using deep well 21mm socket
5) Remove the bolts from the transmission cross member to frame using 18mm end wrench and 15mm socket
3) Remove the Fuel Vapor Canister using 10mm end wrench (soley for the purpose of allowing the drivers side bolts for the cross member to slide out). If you use a socket instead of a wrench, proceed to 3A and 3B, if you use an end wrench, skip to 4
3A) Break a nipple on the fuel canister beacuse it is too close to the bolt you are removing
3B) Plastic weld repair the fuel canister
6) Remove the transmission cross member
7) Remove the transmission mount from the transmission using 18mm socket
8) Jack up the transmission
1) Disconnect the exhaust at the turbos using 15mm socket with about 20 inches of extension and a universal joint
2) Disconnect exhaust at the back of the y-pipe using 15mm socket
12) Remove tranmission pan
13) Remove filter using 12mm ETorx-Plus (good luck finding one. As seen later in the linked thread, most just grind down a regular Etorx from harbor freight)
14) Ensure all 3 rubber pickup tubes for the powerboost specific pickups are properly placed into the transmission (see pictures later in thread). These most likely are floating around in the fluid you removed or the pan.
15)Reassemble

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[Ajzride]

I was finally able to get the pan out.

For a powerboost you have to drop the transmission cross member so you can take the transmission mount loose. The FSM does not show the cross member being dropped, but the mount bolts are so long they can't come out unless you drop the cross member.

To drop the cross member you have to remove the Fuel Vapor Canister because it blocks the cross member bolts from sliding out (THIS IS ABOSLUTELY STUPID, if the bolts had been put in from the front the nut would come right off, but since the bolt is inserted from the back, you have to remove the canister).

Be extremely careful, it's easy to break a nipple on the fuel canister (ask me how I know)

With the cross member out, the tranmission mount removed, the rear exhaust disconnected, have a buddy do a pull up on the end of the exhaust while you wrestle with the transmission pan. You will get just enough clearance to shove it out (sending the remainder of the trans fluid everywhere). Wear gloves while you do this because all of those sheet metal heat guards under there have sharp edges (ask me how I know).

Now I have to borrow a buddy's car and go buy some e-torx sockets becasue the filter is not held in with a standard bolt.

 

[Porpoise Hork]

I have been a staunch beliver that the engineers designing modern vehicles should be mandated to actually perform service work on them. If this were done then I can absolutely guarantee you stupid design layouts like this shit would stop...

 

[oneinch]

Sounds like quite the chore. Are you going to reuse the pan? If so, what's your opinion on if it is possible to put a drain plug in the plastic pan?

 

[Porpoise Hork]

Sounds like quite the chore. Are you going to reuse the pan? If so, what's your opinion on if it is possible to put a drain plug in the plastic pan?

No one makes an aftermarket pan for the PB. As for putting a drain plug in the plastic one, it'd be far more trouble with the potential for leaks than it's worth.

 

[oneinch]

@Porpoise Hork , You're probably right. I want to think that sealing around an added drain plug should be possible. Sealants and gaskets can handle the oil, temperature, and pressure. I don't know what kind of clearance there is inside the pan for any sort of drain plug. Plastics and caps are used elsewhere to hold in fluids, why not the trans pan? Oh well, what do I know? I'm just a guy with Internet access. 🫡

 

[FaaWrenchBndr]

Well, the one thing you need to keep in mind is this.

Engineers create build strategies for efficiency and ease for the assembly line process. They do not, and they never have, assembled vehicles with the mechanic in mind.

Removal of the exhaust makes it quite a bit easier.

 

[FaaWrenchBndr]

Sounds like quite the chore. Are you going to reuse the pan? If so, what's your opinion on if it is possible to put a drain plug in the plastic pan?

There’s not enough material in the proper places to mount a plug in the plastic factory pan

 

[Ajzride]

The oil filter is held on by an E12... however the bolt is right above the exhaust and there is not enough room for a socket. I can't find an E12 wrench locally. I'll have to wait two days for an E12 wrench or drop the entire exhaust system

Just pay the dealership.

 

[XLT22]

That's why I dropped the y-pipe. Makes it easy peasy.

 

[Ajzride]

That's why I dropped the y-pipe. Makes it easy peasy.

How do you drop the y-pipe? At the turbos? I can't find a combination of extension, sockets, ratches, impact guns, and universal joints that will work to actually be able to turn the nuts on the exhaust. it's really tight on a powerboost up in there.

 

[Ajzride]

The E-Torx sockets I have are tapered:

The head of the bolts holding the filter is only about 1mm thick, so this socket won't work. Make sure you get e-torx sockets that are squared off and not tapered.

 

[Miko]

In my PB, I can slide the oil pan without damaging the exhaust system. It's not easy, but it's possible. After the first oil change, I replaced the oil pan with a model with a drain plug

 

[Ajzride]

In my PB, I can slide the oil pan without damaging the exhaust system. It's not easy, but it's possible. After the first oil change, I replaced the oil pan with a model with a drain plug

You mean the transmission oil pan right? Not the engine oil pan?

How did you get the filter off? I'm thinking there might be two different filters. The one Orielly's sold me has a bolt on either side, but the one that is in there from the factory has two bolts at the back, right under the exhaust crossover.

 

[Miko]

Yes transmission oil pan. My filter looks like this https://www.rockauto.com/info/257/20072.jpg

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