Motorcycle Repair: Stripped Trans plug, machinest, flhr


Question
Recently purchased a 1994 RK FLHR. Just did 35K service and found my trans plug will not tighten to 7 ft-lb and pulled some threads out with the plug. It is secure now and not leaking but I don't feel comfortable for a long ride with this situation.   since the plug goes through the oil pan, are the trans plug threads in the oil pan or will I have to replace the trans housing to fix this problem. I can't tell from looking in the manual and did not feel inside before I put the plug in.  Don't want to remove it again until I get ready to repair it. It may leak next time. I am a novice mechanic but have decent ability and tools and feel confident I could replace the oil pan following my manual but a trans housing is not something I relish. Give me some good news...

Answer
There are two ways to go on this repair. One is remove the pan and replace it. The way I do it is remove the pan and install a steel insert. That way it will never pull the threads out. Installing the steel insert would require a machinest to do the work, but it is permanant. Either way the pan will have to be removed to fix it.
Good luck and happy riding
Mike