Help, Please! Stuck Transmission Oil Filler Plug

[tmarx]

1985 Targa, 915 transmission.

So apparently the PO (or his mechanic) hadn't read 101 Projects when last changing the transmission oil and overtightened the filler plug - to the point of rounding it off to some degree. I've got the 17mm hex and it's fitting loosely and not getting enough "traction." It doesn't spin, but it doesn't stay in straight.

Worse yet, I made it a much bigger problem by (stupidly) draining transmission before removing the filler plug. So I've got a dry transmission and I can't get the filler plug out.

Any suggestions for tricks to getting that stuck plug out would be GREATLY appreciated!

Thanks,
Nate

[tmarx]

BTW - I did search the forum and I'm reviewing those now, but thought I'd ask again as well.

Thanks.

[yelcab1]

Where are you in the Bay area?

I will come over with my welder, we can weld a nut, a bolt, a socket onto your filler plug and sacrifice it.

Get a new plug.

[Bobboloo]

I would put a 17mm impact wrench on it if possible or you could weld a fresh 17mm nut on top of it.

If no impact or welder is available then you could file the sides down enough to hammer a 5/8" socket on it.

[Eagledriver]

Heat may help. Heating the case will cause it to expand more than the steel plug. Another option would be to put the fluid in through the vent on top of the tranny. Might have to do a "partial drop" to get access.

-Andy

[usurpah]

You didn't mention if you've used any fluids on the plug. Try soaking the threads in Kroil for a day and then hit it with an impact wrench as Bobboloo mentioned. Order a new plug from Pelican today.

[tmarx]

Originally Posted by yelcab1

Where are you in the Bay area?

I will come over with my welder, we can weld a nut, a bolt, a socket onto your filler plug and sacrifice it.

Get a new plug.

Unfortunately, I'm not very close - Novato.

[James Brown]

Try it with a pipe extention and pull real slow increasing your torque on it, then brake out the welder.

[m110]

Welding on a nut would be my last resort but will surely work...it is a pain. Try heating the case, soak in Kroil the night before. You could also sacrifice a 12 point Allen style socket by pounding it in and cutting into the rounded lands with the 12 points of a slightly larger size.

[tmarx]

Thanks for all the tips. One follow-up question -

Could I pump a full jug of oil (more than spec) through the drain plug and then replace the plug while it's gushing out? At least then I could get it somewhere with a lift rather than doing all this laying on my back with limited space.

Thanks again,
Nate

[James Brown]

you could do that but just flip the car on it's roof, then you won't spill any.

[ninelevenick]

I had this happen to me before. My filler plug was sticking out of the case about 3/16" or so. This was just enough meat for me to use a pair of vice grips. Using a piece of pipe for extension/leverage, I was able to loosen the plug.

[bell]

grind your 17mm hex so it's totally flat on the bottom, most of these have a slight rounding on the bottom, by making it flat you should get enough bite in the plug........heat too.....

[glewis80SC]

Had this happen too, tried the heat with no success. Welding finally did the job. i do like the idea of grinding down the hex so its flat though.

[don gilbert]

take a pointy punch, pound in an indention, then tap it counter clockwise out with the punch and hammer.

[vulcan300]

Definitely soak in Kroil or another penetrating lubricant first. Mae sure you scrub around the dran plug and spray with cleaner so that the penetrating oil can actually get into the threads.

Then put the 17 mm hex in the drain plug, use a large pair of vicegrips and tighten on the outside of the drainplug so that it is bent into contact with two flat edges of the hex. You can do this at two or even three positions and then just leave he vice grip in place for a little added grip. Then use your socket, a bar type socket wrench and a pipe extension if you need more torque.

This should get your fill plug out. If this doesn't work the welding thing is the next best bet.

[windsoreight]

Don't know if you have the room but if have any of the plug exposed a small pipe wrench would probably do the trick. I just serviced mine and I know the fill is in a tight location.

[tmarx]

Thanks everyone! Victory was had through the following:

1) cleaning and then dousing with PB Blaster; soak for 1/2 hour;

2) using NAPA valve grinding compound to give the hex wrench more bite on the somewhat rounded edges; and

3) hanging a box wrench off of the end of the hex wrench and then using my jack to push up on the other end of the box wrench, thereby torquing the hex wrench.

Drives me nuts when a single-star difficulty job takes me five hours. Makes me hesitate to do anything that could be tricky! Anyway, new plug from Pelican is on the way. And, to tie this into a previous thread, I used Kendall NS MP. Hope to feel a difference - even a small one.

[wildcat077]

Nate,

There is another plug on the right hand aft upper end of the transmission that you could use to fill your tranny...

Should this ever happen to anybody else,jack the rear end of the car and remove the right side rear wheel and you will see the plug.It looks similar to the filler plug and if you drain the tranny completely all you have to do is put back in the proper amount through this hole.
It will keep your car in a driveable state until you can eventually remove the filler plug...

It worked for me !

Cheers!
Phil

[DUK]

Just wanting to make sure you are using the right Kendall oil. I don't think the NS MP is it.

This is...
Glocker Oil 33256 Kendall Axle Gear Lube