Help with identifying 915 Transmission fill plug type

[Esel Mann]

Hi guys,

I've run into a problem which I hope someone out there may have the solution or know what is up.

I want to change the transmission fluid in my 915 type transmission. In doing so I was going to order a new fill and a new drain plug (from our host) and change them out at the time of fluid drain and refill. According to our host's site the drain and fill plugs are the same (999-064-020-02-M260). Thus both have the magnet.

The problem is, the last time I changed the transmission fluid, I attempted to use the same plug (new of course) for both drain and fill locations per the host's website recommendation. I found there was a clearance issue inside the transmission for the fill plug and thus the fill plug would not properly seat as the magnet was coming in contact with something within the transmission. Fortunately the original fill plug was in sufficient condition to re-use. This particular fill plug has no magnet and thus no clearance issue with the metal object just inside of the transmission at the fill hole.

I called our host's customer service in hopes that they could point me to the fill plug with no magnet. I was informed that it has been superceeded by the one with the magnet, there no longer are any without the magnet, and there should be no clearance issues.

So, has anyone successfully used what I consider the drain plug as a fill plug for the 915 transmission say on a circa 1984 911?

Aside from me re-using the original fill plug are there any recommended alternatives?

Any help or insight is much appreciated.

Regards,

Carlton

[Grady Clay]

Carlton,

I will admit ignorance to the current parts. From my experience, the magnet is epoxy in place. You can remove it.

Best,
Grady

[barney911rs]

I don't understand why you need to keep using new plugs?? for the allen style, unless it's been buggered up, there is no reason to change them I'm aware of. I have the old style hex head versions and they work just fine after years of service. They use a pipe thread, so they seal by themselves when they tighten up. DO NOT use teflon tape, as it can break off and clog up oil passages.

The transmission plugs do not use a sealing washer, that is on the oil tank and sump cover if you have that style.

[Esel Mann]

Grady -

Your idea is a good one and worth trying. Heat the magnetic version of the part up to loosen the epoxy and then try to gently twist the magnet out. On my prior transmission fluid change, I attempted to remove the magnet using vise-grips. No heat just raw power. It simply crumbled and thus I was forced to re-use the original fill plug.

Barney911rs -

I concur regarding the washers. I believe it is the oil tank and crankcase oil plugs which have the sealing washer. The transmission pluqs I have are headless and thus a washer is not possible.

From what I understand, the reason why you would/should change the xmssn drain plug is because of the magnet. In the prior fluid change I also attempted to remove the metal filings from the magnet. No matter how hard I tried all I would do is simply push the filings around. By using a fresh plug one has a baseline for which to monitor the metal which accumulates on the magnet from fluid change to fluid change. Typically filings are normal, but none the less starting from no filings will at least allow some form of subjective analysis.

Now I am not sure why one would change the xmssn fill plug (presuming no magnet) every fluid change. My motivation to change it this time (like last time but unsuccessfully) is because it is the original and hex area is well used. While I personally have not experienced the nightmares of removing these plugs. Others have. I can't see with such light torque spec as there is for the xmssn fill plug how on earth it could manage to be so hard to remove, however, I want to hedge a bit and ensure that I have a fresh hex area, just in case.


I am still totally baffled as to how anyone is getting the magnetic type plug into the fill hole of a 915 type transmission!


Regards,

Carlton

[Early_S_Man]

John,

The problem with the inhex plugs that require an Allen-drive bit [same 17 mm as prehistoric 356 and air-cooled VWs used] is that the plugs are aluminum, and quite easy to damage! The 'good' old steel 915 plugs that use the 19 mm lug wrench, or other 6-point socket have become NLA. It is a real shame to see the factory use aluminum to save a few grams in the WRONG application, for sure!

My suggestion is to keep a look out on eBay for the male hex steel plugs, or see if a VW dealer or specialist can get the steel plug for an old Beetle, Bus, etc. All use the same M24 tapered pipe thread. I have to assume it would be a waste of time to try and get a steel inhex plug for a 901, 911, or 914 transaxle at a watercooled-oriented Porsche dealership these days???

[RWebb]

use a cloth and 'pinch' the filing between layers to get rid of them

don't waste $$ on new plugs all the time!

[barney911rs]

Warren, I did acknowledge that the newer plugs get damaged. You are correct, the factory should have continued with the hex head steel plugs. The allen head are a PITA.

Carlton, I never had a big problem getting them clean. Randy's method works, but I've also cleaned them in a parts cleaner. Vigorously scrub with the brush while fluid pours over it to carry off the bits. Wipe clean and dry with a clean rag. If you have a fill plug that works, use it. If you feel compelled to get a new drain plug, then that's your prerogative. Since there are no issues with that one, the new plugs will work just fine.

[Esel Mann]

Guys thank you all for your insight.

Please note that I used the term hex in one of my replies. What I really meant was in-hex (or allen). Sorry if this caused any confusion.

I very much understand the points and suggested cleaning methods for re-use of what I have (both fill and drain). The recommendations are certainly valid so long as the part has no issues, for example buggered in-hex area, corrosion which won't clean off, chipped magnet (the magnet material is very brittle), and the like.


I have ordered an extra xssn drain plug. I am going to try to see if I can somehow easily remove the magnet and thus make it usable as a fill plug.

I have also poked around on one of the parts diagrams (I can't recall which model year) and found an in-hex plug. I am going to see if it fits.

I will report back as to success failure of either so that in the future, if someone finds themself in a situation whereby they do need to replace the fill plug on a 915 xmssn there will be some form of searchable information (this post) which contains what has been tried in substitute for what appears to be a NLA original part (note I have not tried to obtain the part through a dealer, perhaps that is still possible).

Regards,
Carlton

[oldschoollear]

I'm reviving this thread because I too am having problems. I can't get my fill or drain plug to budge, both have a yellow substance around the exposed threads. The tranny has been rebuilt, do you guys think someone used something like loc-tight on the threads? Any suggestions? Thanks

[oldschoollear]

Just stripped the fill plug head, crap. Any ideas on getting it out?