Question about 915 oil plug removal

EdT82SC · 10-12-2003, 07:07 AM

After reading multiple threads about replacing the gear oil in a 915 I felt ready to do it for the first time. I have a 17mm hex from Sears. When I put it in the hole in the plug it was very loose. Much too loose to turn it. I tried putting the hex key in a 17mm socket to see if it's thr right size. It fit pretty well with just a little bit of play. So I measured the width of the hole on the drain plugs, and one is 17.5 mm and the other 17.7 mm. The hex key measures 16.2mm. So I'm guessing that the oil plugs have been mistreated over the years.

Has anyone seen anything like this? I'm thinking about getting an 18mm hex since it will probably be 17.2 mm, and may fit the holes. Does this sound good, or am I smoking crack?

jmohn · jmohn's Garage

Uhhh ... if you've really got a 17 mm hex, it should measure 17 mm. Better check it, you may have the wrong hex wrench.

Jerry M
'78 SC

Early_S_Man · 10-12-2003, 08:33 AM

Ed,

There are several ways to get the old plugs out ... including 'shimming' the hex drive bit you have with a bit of plumber's strap, but it does need to be a very tight fit in order to get a good bite and not worsen the current damage!

My strong recommendation is to get a pair of new replacement steel plugs from a VW dealer [for an air-cooled Beetle/Bus transaxle] before you proceed with trying to change the gear oil. The original plugs for 915's were steel and could be removed with the lug wrench ... and were seldom damaged! I have been told that they are NLA, now.

red-beard · red-beard's Garage

I would order a new plug. If the plug seems bound in the case, use a torch and heat the case around the plug. Keep moving the heat around the plug but you want to heat the case. Keep checking with the wrench until it goes free.

James

rfuerst911sc · 10-12-2003, 02:45 PM

All good advice,one additional piece is make sure you remove the fill plug first,this will stop the chance of getting the tranny drained and not being able to fill.I really think the smart thing to do is replace the plugs with a plug with a hex head,as described above as VW plugs,plus put a little anti-seize on the threads and you should never have a problem again.

pwd72s · 10-12-2003, 04:28 PM

One way to test to see if the 17mm hex is indeed 17mm? Put a 17mm wrench or socket on it, see how they fit. Tip...a long socket makes a nice handle on a hex...much easier on the hands.

47silver · 47silver's Garage

hi
i would purchase a socket with a 17mm allen bolt combination.. that way you can use a breaker bar an allen wrench is hard to use and may only cause problems, imo.

gary

CrossT · 10-12-2003, 06:47 PM

I had the same thing happen. As James [Red-Beard] said, order a new one. I was barely able to remove my lower one due to the expansion. Ordered a new one and will install next time I change oil out.

todd
86 cpe

EdT82SC · 10-15-2003, 09:16 PM

I picked up the two new drain plugs from PP today, and the 17mm allen wrench I have fits perfectly in them. So this weekend I'll remove the bad plugs, put in some Swepco, and put in the new plugs. Thanks for the great advice, everyone.