Originally Posted by uberrogue
96 Cherokee 4x4 AW Tranny
Long story short replaced the transmission filter and while torquing the screws the middle one in the rear broke off. There is a cross member that is in the way of anything going straight in.
Any easy way of removing the broken screw (whole head is missing) without removing the crossmember.
I was considering dremelling a notch or even possible removing the crossmember.
Screws are M6-1.0x15m/m or 20m/m (I don't recall the length,) and I typically replace them with socket heads and flat washers (easier to handle.)
If I'm in a hurry, there are enough screws under there (nineteen?) to share the load out, I'll daub a bit RTV in and around that screw hole in the gasket to help it seal. Not much, and not anywhere else.
Those screws are exposed to enough that I usually just replace them every time I drop the pan - when I had rigs with automatics, I just bought the screws & washers by the box.
Drilling that screw out will be a bit difficult - you'll have to remove the crossmember to access it properly, make sure to centre punch/drill the centre
of the screw (so you don't chew up threads!) and I wouldn't use a bit larger than 5/32" if I could get away with it. A left-hand twist drill bit will often grab the screw and rip it right out without further headache.
Worst case, get a HeliCoil kit (you'll want a wire insert - there's not quite enough material there for a bushing,) overdrill/overtap the hole, and put in the insert (you could
use an M8-1.25 screw or a 5/16"-18, but that gives you one odd screw to keep track of, and that's a headache. Better off just fixing it right - I know HeliCoil kits can be spendy. I have many of them, accumulated over the years...) You can get a kit with the proper tap and drill bit in, which saves you having to figure it out yourself.
The fact that there's no pressure on that join it also a factor in your favour - just gravity, submersion, and splash. This makes it easy to half-**** the job (although I don't if I can avoid it, that's just not me.)