Transmission fill/drain plugs frozen

[lmcchesney]

With the tranny out, I am trying to remove the fill/drain plugs but they will not move. 17mm size. I have done the penetrating oil and have used the pipe extension on the socket. I believe these are Al. Any experience in getting these free?
Thanks,
L. McC

[silver2.0]

Well, you have tried what I would start with, maybe try some heat. Make sure the area is clean first, and only heat up around the plug. Obviously don't get it extremely hot. I can't remember if the transmissions for our teeners are magnesijm or not, so don't get it red hot. And if there are any shavings it will ignite fast. Don't worry about the oil starting on fire, it won't. My only concern would be to find out if it is magnesium first, and make sure there are no shavings. You can actually weld magnesium, and heat up the case pretty good, but the shavings will start with very little prompting, and once it starts, it's toast. Would there be enough room to get an impact wrench on it if you used swivels? That would be the better choice, if it can be done. Good luck!

[Dave at Pelican Parts]

It is a magnesium case. The plugs are steel.

Heat, get a bigger wrench, beat on it. I have found that hitting the head of a bolt (parallel to the shaft of the bolt) can help loosen it if I'm pulling on the wrench at the same time. I think the same would hold with these plugs.

Remember, remove the fill plug first.

--DD

[red-beard]

Heat. Heat works every time. Heat all around the plug and then try a wrench.

Heat some more.

Wrench

Repeat until it loosens.

Replace plugs....use anti seize....

James

[lmcchesney]

Thanks all.
Well, can't find a 17mm allen wrench. Found that the head of a 17mm bolt fits the drain plugs well. Moved the transmission outside, got the fire extinguisher, propane torch. Filed the threads to the bolt flat. Large vice grips and 4ft. of pipe. Heat, Heat, Heat. See oil bubbles arround the edge of the drain plug. My son torques the bolt, eventually, the bolt shears. Several bolts later, drain plugs still in.
Anyother suggestions?
L. McC

[tat2dphreak]

buy the right tool... I bought mine from toolsource.com for $4... any VW shop will have them too...

I just did this... I have a 3' long, 1/2" break over bar... a little PB blaster and that did the trick... you may need to use heat, but having the right tool is worth a fortune!!!

[Dave at Pelican Parts]

Yup, bolts don't cut it for the exact reasons you have just found out. The Right Tool is available from us, from just about any VW Bug shop... And you can get the Massive L-Shaped Allen Key (OF DOOM!) from Sears, and probably an Allen socket in 17mm size as well.

--DD

[tat2dphreak]

yup, mine's the 1/2" socket... it rules!

[lmcchesney]

Found a 17mm hex end socket. Put the torque wrence on. Heat, heat, and then hotter, liberal application of grutting and swearing, ----- it moved.
Thanks guys. The right tool does make a difference.
L. McC

[tat2dphreak]

IMHO... don't use a torque wrench... it can really jack them up, and a break-over bar is 100 times cheaper...


get the longest break-over bar you can find...

[Dave at Pelican Parts]

Ouch, yeah! Talk about not using the right tool... The torque wrench is an instrument for measuring torque--a breaker bar or T-handle (or a really stout ratchet) is an instrument for applying torque. There's a definite difference!

--DD

[lmcchesney]

Sorry, wrong terminology. Torque as in 1/2" ratchet and long pipe.
L. McC