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How to change transmission pan gasket - 2003 Harley Davidson FLHR Road king

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Drain the engine oil and transmission oil. Remove the bolts and drop the pan. Install a new gasket and reinstall the pan. No problem. I usually allow the transmission to sit overnight if I can and let most of the oil drip out.

Good luck
Steve

Posted on Oct 03, 2010

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With the fluid pan removed use a blunt screwdriver to scrape off the old gasket from the pan and the transmission body. Apply a thin smear of sealant to the pan and place the new gasket onto it - line up the holes in the gasket with the bolt holes in the pan.

Lift the pan up against the transmission body and put the bolts in finger tight to hold it into place, then tighten with a socket to pull the pan tight against the transmission body.

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Fluid & Filter Change Under normal service (moderate highway driving excluding excessive hot or cold conditions), the manufacturer feels that automatic transmission fluid should not need periodic changing. However, if a major service is performed to the transmission, if transmission fluid becomes burnt or discolored through severe usage or if the vehicle is subjected to constant stop-and-go driving in hot weather, trailer towing, long periods of highway use at high speeds, fluid should be changed to prevent transmission damage. A preventive maintenance change is therefore recommended for most vehicles at least every 90,000 miles (145,000 km).
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  1. Raise the car and support it securely on jackstands.
The torque converters on some transmissions are equipped with drain plugs. Because it may take some time to drain the fluid from the converter, you may wish to follow that procedure at this time, then come back to the pan and filter removal.

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Before removing the transmission fluid pan, insure that the area is clean of dirt and debris

2. Place a large drain pan under the transmission.

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Loosen all of the pan attaching bolts to within a few turns of complete removal


  1. Loosen all of the pan attaching bolts to within a few turns of complete removal, then carefully break the gasket seal allowing most of the fluid to drain over the edge of the pan.
CAUTION DO NOT force the pan while breaking the gasket seal. DO NOT allow the pan flange to become bent or otherwise damaged.

  1. When fluid has drained to the level of the pan flange, remove the pan bolts and carefully lower the pan doing your best to drain the rest of the fluid into the drain pan.ea833e6.gif


Once the pan is removed, discard the old gasket and insure that the mating surfaces are clean

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Inspect this magnet inside of the pan for any large pieces of debris. A light gray coating is normal

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Clean the pan thoroughly with a safe solvent and allow it to air dry

5. Clean the transmission oil pan thoroughly using a safe solvent, then allow it to air dry. DO NOT use a cloth to dry the pan which might leave behind bits of lint. Discard the old pan gasket.

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The transmission filter is secured by a mounting bolt (arrow). Some models may use two bolts

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Remove the filter mounting bolt ...


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... then pull the filter free from the transmission

6. If necessary, remove the Automatic Transmission Fluid (ATF) filter mounting bolts, then remove the filter by pulling it down and off of the valve body. Make sure any gaskets or seals are removed with the old filter. The transmission usually has one round seal and a rectangular gasket.

7. Install the new oil filter screen making sure all gaskets or seals are in place, then secure using the retaining screws, if applicable.

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Install a new pan gasket


8. Place a new gasket on the fluid pan, then install the pan to the transmission. Tighten the attaching bolts to 71-119 inch lbs. (8-13 Nm).

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Fill the transmission with the proper amount of ATF

9. Add three quarts (six quarts if the torque converter was drained) of fluid to the transmission through the filler tube.
10. Remove the jackstands and carefully lower the vehicle.
11. Start the engine and move the gear selector through all gears in the shift pattern. Allow the engine to reach normal operating temperature.
12. Check the transmission fluid level. Add fluid, as necessary, to obtain the correct level.

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Fluid - A/T: Service and Repair
Transmission Fluid and Oil Filter Changing
REMOVAL PROCEDURE
1. Raise and suitably support the vehicle. Refer to Vehicle Lift Points.
2. Place drain pan under pan
3. Remove oil pan bolts from front and sides only.
4. Loosen the rear oil pan bolts approximately four turns.
5. Lightly tap the oil pan with a rubber mallet or pry to drain the fluid from main case.
6. Remove the oil pan bolts from rear oil pan and gasket.
7. Remove front oil pan bolts leaving one corner bolt in loosely.
8. Lightly tap oil pan with rubber mallet or pry to drain fluid.
9. Remove the following remaining components:
^ The front oil pan bolts
^ The oil pan
^ The gasket
10. Remove the oil filter bolts and filter.
11. Clean the following components:
^ The transmission case
^ The front adapter case
^ The oil pan gasket surfaces with solvent
^ Air dry
^ All traces of gasket material must be removed
INSTALLATION PROCEDURE
1. Install the gasket.
2. Install the oil filter.
3. Install the bolts.
^ Tighten the transmission oil filter bolts to 20 Nm (15 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
4. Install the front oil pan.
5. Install the front oil pan gasket
6. Install the front oil pan bolts
^ Tighten the front oil pan bolts to 11 Nm (96 inch lbs.).
7. Install the following components:
^ Install the pan
^ Install the gasket
^ Install the bolts
^ Tighten the oil pan bolts to 11 Nm (96 inch lbs.).
8. Refill the transmission with DEXRON III through oil pan fill plug on the side of the (main case) oil pan. Fill the transmission to lower edge of oil
pan fill. Fill plug opening using and oil suction gun.
^ Tighten the oil pan fill plug to 45 Nm (33 ft. lbs.).
9. Lower the vehicle.
10. Check the transmission fluid level. Refer to Transmission Fluid Checking Procedure.

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1 Answer

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Most affordable possible solution is to give it a transmission tune-up. Transmission number one problem is neglect. Change the oil, filter and pan gasket. You'll probably need to take the pan off, very messy job. Take the pan off, carefully scrape all old gasket material, clean the pan with dish washing soap, dry it completely, put a bottle of Lucas for transmission in the pan. Put some Indian Head Gasket Shellac Compound on the pan gasket surface. Set the gasket on the pan, keep the gasket on the pan for three minutes then install. Don't put any Shellac on the transmission gasket surface nor on the gasket. Follow recommended directions for filling the transmission with oil.

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