Looking for options
I have 65,000 miles on a 2004 STD I bought new.
A few years ago a shop cross threaded my drain plug, it hung on for a lot of
years but it just let go.

 

The obvious solution is a thread repair. There are various inserts available, but they all require special tools for a successful result. I suggest you ask around locally with dealers and indys, small engineering shops, to find someone with the right skills and tools. Go with what is available!

It may be possible to repair in the bike, but will be easier with your trans on the work bench, so factor in that possibility.

 

Does anyone know how many hours it would take for a transmission replacement.

 

I bought an 02 FLSTC new and stirpped mine out the very first time I changed tranny oil. 95,000 miles and several changes later it's still (barely) hanging in there. Did you ever get yours fixed? I just retired this month and plan on doing a lot of traveling this yr. Kinda concerned about the plug. It's not leaking or anything. Just hanging in there.