Drilling out the tranny drain plug...

[djmcmath]

Seems like changing the transmission oil ought to be about a 45 minute job, tops. Only problem is that the guy who put the plugs in last time was either a gorilla or a guy with an impact wrench. The fill plug came out with some significant effort, but the drain plug stripped out completely.

So I went down to Sears and picked up a couple of drill bits and set to drilling out the drain plug. I've made a lot of progress over the last several days, but I'm really getting sick of this. Are there any alternatives? Is there a better way to remove a stuck tranny plug? Having started in on this, how much damage have I already done? Is there anything I ought to be doing to keep from doing any more damage?

I'm going to go back down and grind away on that stupid thing for another hour or so. Thanks in advance for the help.


Dan

[Doug Steinel]

How about a picture so the guys can see exactly what you have done. Perhaps a torch would have helped before you mauled it.

[rcecale]

Dan, how about just drilling a hole up the center of the plug and using an Easy-Out ?

Randy

[Randy Webb]

As above but buy a left hand drill bit and use that with the drill in reverse -- it amm back the plug out....

[djmcmath]

Thanks for the quick replies. Here's a pic to give you an idea what I've done to screw it up already...

[djmcmath]

I think it's too late to drill a hole up the center. My strategy was to put three holes around the edges, then use successively larger drill bits to widen them out until they met in the middle. According to my theory, that should break the strength of the bolt and it should fall out with just a little coaxing.

Do they make easy-outs large enough to do something this size?

Left-hand drill bit, used in reverse? That would be just like using a normal drill-bit in forward, except it would apply some torque in the "make the nut looser" direction ... That's a good idea. Thanks, Randy.

[scottb]

I'm not an expert, but it looks to me like you're committed to finishing it that way. Once you get as much material out as possible with the drill, I'd use a Dremel to grind out as much as you can without harming the threads. Then, use a pick to remove the remaining threads stuck in the drain hole threads. My $.02, FWIW.

(ps: You're in Seattle. If all else fails, flat bed it over to John Walker and let him do his magic.)

[djmcmath]

Yeah, Scott, you're probably right. I was thinking through the Dremel grinding wheel thing while I was down absorbing tiny shards of metal this afternoon. (sigh) Oh, well. Thanks again for the replies, all.

Dan

[Doug Steinel]

Dan,

I think you have a reasonable strategy... now do it. When you remove much of the center, you will be able to work the rest out and, if careful, not harm the threads. Then put the new one in with a torque wrench. Everytime you drain the tranny, you will be reminded of this experience.

[power]

Looks like it may be difficult to get an easy out in there now. You may be able to get enough purchase in one of the drill holes to take a hammer and punch and strike at angle to get a rotating torque on the plug. (I have a couple of sets of different sized punches that have worked in similar situations in the past) but then again, I am fond of hitting things with hammers ect.......

[scottb]

Originally posted by power
You may be able to get enough purchase in one of the drill holes to take a hammer and punch and strike at angle to get a rotating torque on the plug.

I had the same thought. If you can get at it at enough of an angle, and heat if first, you might be able to get it out. Just be VERY careful not to bugger the threads.

[djmcmath]

FWIW, I'm figgering I've buggered the threads already. If I somehow come out lucky and discover I haven't destroyed whatever gears are on the other side of the plug, too, I'll be a pretty happy camper, at this point.

The worst part about it isn't the little metal shards that the drill sends spinning into my arms, face, and hands -- it's the BIG metal shards... Yes, I'm wearing long sleeves and facial protection, and it still sucks, so for those of you who haven't yet overtorqued a transmission drain plug, I cast my vote against doing so.

I was actually thinking about using a hammer 'n' punch to separate the bits inside the hole. Once I've cleared enough of the material out with the drill, then I can apply a punch to the outside, in hopes of breaking it apart. Hopefully, it'll all come out together, and won't have melted itself into the threads somehow. Thanks again for all the help. I love this board...

Dan

[Doug Steinel]

Dan,

I would be concerned about getting metal shards into the tranny once your break through. Maybe you would have to somehow flush out the tranny a few times. I would be concerned.

[rcecale]

Dan,

I'm not so sure an easy-out WON'T work. I've used them on much worse cases. Just drill deeper into the hole I've circled and have at it...you still may be able to get it this way.


A trick I've found to work is once you get the easy-out to bite, rotate it slowly while tapping it with a hammer. It helps to keep the grip strong.

Randy

[djmcmath]

Ok, I'll pick up an EasyOut on my way home from work today, then. Just about anything would be better than drilling this thing out completely. I'll let you know how it goes.

As to metal shards inside -- yes, that does worry me. I have a gallon of cheap tranny oil I plan on using to flush with. It might make sense to flush twice, now that I think about it. For $9 in oil, I can potentially save myself a $$$ rebuild ...

Dan

[RickM]

Personally, I would take the tranny to a machine shop and have them remove it. I'd also be worried about shards and causing (any or more) damage to the case. They may be able to weld a hex piece of metal in there and impact out. Or mill the center section of the plug smooth and deal with it that way.

For the few dollars save youself the grief and any permanent damage.

[masraum]

Wow, that sucks. Keep us updated on your progress and good luck!

[scottb]

Rick's advice is good. This whole thread has been giving me the "willies," frankly. If you don't know a machine shop, just take it to John Walker. Let him decide what to do, and let him do it. Don't hang around to watch, as it could get ugly! (Like watching sausages being made.) At this point, I wouldn't drive it. Use a flatbed.

Dan, use this as a learning experience, but don't go from bad to worse. Let a pro finish the job.

[NoLift911]

BTDT....

Now that you have the edges raised and flared out take a cold chisel and work them toword the center of the plug. Eventually what will happen is the plug caves in on itself around the edges.

Then slowly work the plug out...it will begin to turn in the threads since most of the pressure is off. I used a small scredriver to work out the remaining pieces.

Next thing was to buy a powerful telescoping magnet and bend the tip to fit in the hole to get out any shavings etc.

Next forcefully load the top hole of the tranny with fluid and flush out any remaining pieces.

Next fill, drive for 100 miles and then drain jusst to be sure.

Overall patience is the key, took me about a week to get mine out a little bit each night...the case itself is pretty tough. Can't tell it ever happened on mine and it looked worse than yours.

-Jeff
nolift911@hotmail.com

[Hugh R]

Use the biggest ez out that you can get in there.