yeah it seems to be a common thing with this car. Expect the unexpected.
I ended up dropping my pan to make sure I removed all these pieces of metal. Turned out to be a hidden blessing as I realised the filter I fitted was missing the two O rings, meaning there was no tight seal for the trans to suck oil up from the bottom of the pan. this could of been catastrophic if it was left over a period of time.
so here's my tips for successful explorer transmission pan drop:
1. syphon as much of the oil as possible from the dipstick tube. will be 2 less litres you spill on yourself later.
1.5 lift the car as high as possible for ease of access.
2. if yours has one of the exhaust pipes under the pan, the drive shaft at the transfer case WILL HAVE TO be disconnected. easy to do. six small bolts and slide plates away from each other.
2.5 remove pan and filter . fit new filter WITH O rings installed.
3. use degreaser to clean the pan, bots and transmission edge. Ensure any trace of the old gasket/sealant is removed.
4. once everything is clean and dry, apply thin layer of gasket maker to pan edge. place cork gasket on, place bolts trough holes to ensure gasket is perfectly alligned.
5. once dry enough (20-30 min has passed, bolts can be taken out and pan can be replaced.
6. hand tighten bolts starting from the centre bolts and work your way outwards.
7. one resistance is felt by wrench only go another quarter turn or so. again start at centre bolts.
8. replace drive shaft.
9. drop the car. add oil until at level required. done.
great video series on ehow on how to install cork gaskets.
my first uneducated attempt was embarrassing and leaked badly. second was like a pro.
lining up gasket and leaving to dry, plus DO NOT OVER TIGHTEN BOLTS, you'll be fine.
