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Easier said than done and not cost effective. The repair I suggested can all be done and not one bolt needs to be removed...other than the drain plug...obviously....so the threads of the fill plug can be cleaned really well....and the contact cleaner that may get in the transmission can drain right out and not hurt anything.
NO DRILLING OR TAPPING THREADS!
The process JB Weld told me did not even cause me to use a tap to cut new threads. The threads were already there when I pulled out the pipe thread plug.
I have used this process and I have repaired numerous threaded holes and did not need to run a tap into them.
My M20 fill plug has been abused by previous owner to the point the normal plug threads all the way through without being tight enough to get a good seal, even with a ton of Teflon tape. Is there a slightly oversize plug available? Any repair short of welding and rethreading?
Some pipe plugs work on different tapers, so even if they are 1/2 npt, you may get lucky using for example some from a T5 transmission
NO...The repair was put right back to like it would be originally. The knock sensor can be removed and tightened and did not nor has not leaked since the repair.
I re-created the missing casting with the JB Weld....and did not have to drill or tap any part of the repair. When the JB Weld cured....I could simply remove the threaded pipe plug from the JB Weld I used to create the threads and the thickness of the engine block that had fallen off.