Gearbox filler plug problems

[smurfbus]

Hi,

I have been planning to change my gearbox oil for a little while (clunky box and no evidence of it being done from historic receipts), but seem to have made a bit of a hash of it and so seeking some advice.

I had a go at removing the filler plug earlier in the week using a 17mm hex and spanner, but to no joy, to I lubed the plug, left a while and still to no joy.

The van was in for a little bit of work at my local garage today so I asked the mechanic to just slightly loosing both the filler and sump plug, which he said he duly did.

Under the van later this afternoon and I still can't get the bl**dy filler plug off! I quickly tried the tension on the sump plug and this loosened easily, so either the mechanic didn't do the filler plug, or I'm very stupid and don't know what I'm doing. Just to add to my own misey, I think I have now burred the plug too (see photos https://flic.kr/p/sxyAUw

So my questions are, 1) Is this plug too burred to get out with a 17mm hex now (it is loose), and if so what other tools/method could I use?

2) This does have a conventional thread on it doesn't it?

3) Should I just meekly head back the garage with my handful of gear oil and get him to do it for me as I appear to be useless?

Cheers!

[silverbullet]

Doesnt look that bad. Use a straight/ flat ring spanner on the hex tool and get it as close as possible to the plug, then put a scissor jack under it. Has always worked for me.
I would say get the transmission warmed up before trying anything first, so go for a decent drive of say 20 miles before having a go.
It all helps.

[silverbullet]

PS its a fine taper thread. They dont need to be done up stupid tight...

[itchyfeet]

Are you sure you are turning anticlockwise? Years ago a mate asked me to help him remove his wheelnuts as they were too tight, when I got there he was turning them the wrong way, easy to get it wrong when upside down under the vehicle.

[smurfbus]

Hi Guys, sorry for the delay in replying and thanks very much for thoughts and advice. I have been turning anti clockwise so that's a good start!

Anyway, we're doing what we should be doing and on a trip away in the bus this weekend, so the k this will be a job for next weekend.....

[smurfbus]

Managed to get this filler plug out in the end just using an extended 19ml spanner on the middle for of the hex and came out first time. The sump plug was carrying quite a lot of metal though and a couple of big chunks.

Looking at the photos below, should I be worried about the future of my gearbox?

https://www.flickr.com/photos/marclwood ... res/Hu41eb

Unfortunately since changing the oil I haven't been able to drive it as awaiting a replacement fuel tank.....

[Aidan]

Marc
your box has issues it is fair to say.
This is why regular oil changes are good you get to see and gauge the wear and fix it before it goes bang. Looks like the remains of selector fork bearing shell that have circulated through on their way to the magnet, they can (and do) break and still work perfectly but if you have a shift that is particularly poor then it is probably one of the pair supporting that fork, as a result the synchro slider,ring and fork will be rubbing a little and the big build up sludgy fines on the magnet is one or both of the main bearings through the hardening and on it's way out

[smurfbus]

Hi Aidan, thanks for reply. I've owned the van about 9 months and guessed the oil hadn't been changed for a long time. Fair to say it came out pretty horrible. Only about 3 1/4 litres came out too.....

The box has been a bit crunchy coming out of fourth (apologies I'm a real amateur), a bit of a grating noise, but eased if I double de-clutch and the speed is a bit higher then the change is much smother. No problems with any other changes, even over winter.

What would be your advice on this one?

[itchyfeet]

No quick fix, dig deep and get it rebuit before you breakdown, almost nobody works on their gearbox like you would do the rest of the mechanics on your van, specialist job, specialist tools, don't ask a local garage either.

http://www.aidantalbot.com/live/" onclick="window.open(this.href);return false;
ever wondered why he is so busy^^^

If you can't wait these have been mentioned on here before...
http://www.bearsmotorsport.co.uk/" onclick="window.open(this.href);return false;

[Aidan]

3 1/4 litres is good you can't drain it totally so it wasn't short of oil, could be original, there is no sheduled oil change 100kmiles throw it away and buy a T4 is the VW line

whs/\/\/\budget for rebuild and ensure you have recovery, 4 speeds can be had on exchange from some of the big boys, 5 speeds rarely on exchange, there's a new firm on ebay advertising, I am booked to late September at present

[smurfbus]

Thanks very much for the advice Aidan. On top of the recovery, more worried about a seriously annoyed missus if it ends up going on one of our summer trips!

[smurfbus]

The crunching seems to have gotten worse in the box, and had a moment this weekend where I lost all selection in the box until I finally managed to crunch into third.

Time to book it in with Aidan I think!

[silverbullet]

Soinds like you better had do! Might just get it back in time for the May Day weekend....