Gearbox fill plug removal

[rob1927]

Hello all, could anyone offer advice on removing a seized solid gearbox fill plug!

I was expecting some drama so not that surprised its stuck, so far i tried the 17mm allen key with no joy, i tried belting round with a drift with no joy, i've also applied heat using a gas bottle with a blue flame and then continued with the drift but it won't budge.

The drain plug came open easily with just the allen key and none of the above, i only cracked it loose so at least i can still drive the van, but a bit flummoxed as how to get the fill plug out.

I think half the problem is limited space can't really get a massive amount of purchase on the hammer to hit the drift.

When using heat to loosen a stuck bolt how hot are you looking at to get things moving? Would the bolt have to be glowing red? I don't want to damage the thread in the gearbox.

Many thanks,

Rob.

[Oldiebut goodie]

Use a proper 17mm hex socket on a 3 ft breaker bar, don't mess about with anything less. Amazing how tight they can get eh? My bar has got a lot of stuff moving that nothing else would touch.

[California Dreamin]

17mm half inch drive socket and a 2 foot power bar.

http://www.amazon.co.uk/KS-Tools-911-13 ... mm+hex+bit" onclick="window.open(this.href);return false;

Martin

[rob1927]

Thanks chaps, I'll see if I can get a hold of a bigger bar, I thought it would be tight!

Once it's out, what's the best preventative measure to make next removal easier?

[CovKid]

Dab of copper grease I'd say, Trick is not to overtighten it. It only needs nipping up so it can't work loose but people do over do it.

[rob1927]

Cheers covkid, the story so far, I tried as suggested using a longer bar for leverage but the plug has rounded out, the only thing I can think of is to weld the socket hex tool to the plug but my welding machine is knackered!

Any ideas chaps?

[ghost123uk]

I reckon your weld hex key on should work but....

Just a bit of lateral thinking here = if you find it is not going to come out at all, perhaps this might work. Drain the oil out (point of no return there though) then arrange a bit of hose to fit tightly (wrap with insulation tape?) in the drain hole and run it upwards into the engine bay. Then pour required amount of oil down the pipe with a funnel (plus a bit to allow for the pipe), then quickly remove the pipe and get the drain plug back in. If you do it fast enough not much oil will spill out. Might be a bit messy Oh, hang on, I wonder if a gearbox is airtight ? If it is that won't work

[marlinowner]

Decide that the gearbox oil doesn't need changing/topping up.

[horizontal kipper]

Before i changed my box i had the same problem, ended up draining the oil removing the box turned it over refilled and put it back in again.

[rob1927]

Thanks for the advice, I think I'll go the welder route I don't fancy taking the box out!

[faggie]

run the van first on a long run so everything is nice n warm then undo the gearbox plug

[fairwynds]

In answer to you earlier query....refit using a smear of anti seizure grease (Copperslip or similar) and remember when refitting your new plug (you will be fitting a brand new one won't you !) that the plug threads on the fill and the drain are tapered, so only require nipping up. The taper is barely noticeable but it's there, and time and time again catches people out when they have been wound in tight as a tight thing by some previous spanner monkey! Good luck with it, another job to tick off your list