Transmission Crossmember Will Not Go Back On

[keybrdcowboy1]

Hey guys, hoping someone has some advice to help me.... I dropped my transmission to try and fix an oil pan leak and now I'm putting it all back together. I got the transmission back in and now I'm trying to get the crossmember back in and it will NOT line up... I had this problem a few months ago when I did all this and I was finally able to get the stock crossmember back in with hours of pry bars and hammers. This time around I bought a Stifler's tubular crossmember hoping that would solve the problem.... but it doesn't. I think my issue is that crossmember mount on the driver's side is smushed up a bit (I think from many years ago when I was younger and careless and jacked it up incorrectly...) which I think messed up the alignment. Attached are some pics to help illustrate what I'm saying.... so does anyone have any advice on how I can proceed? Can I elongate the mounting holes to make it match up? Will that change the angle of the trans and driveshaft and cause vibrations? Is there something temporary I can do so that I can get it to a body shop to have them put new crossmember mounts in (I assume they can do that right?)? Any help would be appreciated... thanks guys!

 

[jrichker]

Two possible solutions:
1.) Get a heavy steel block to use as a dolly and hammer both pieces back into shape. There is a twist in the way the brackets line up and one or both may have enough twist to cause the problem. Use some heat to help soften the metal. It does not have to be red hot to do the job.

2.) Drill one or both holes larger so that the bolt fits thru. Put a large washer under the bolt head and under the nut, assemble and then put a jack under the crossmember to raise the transmission. Tack weld each washer in 4 places, tack weld one bracket and washer in one place and the do the other bracket and washer, alternating back and forth between sides. This will help minimize the heat induced distortion.Then remove the bolt, remove the crossmember, put the bolt back in and finish the welding around the washers. The welded in washers eliminate the slop that you introduced by enlarging the holes and help maintain the alignment of the crossmember and body.