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Removing a welded drain plug
Posted: 05 May 2026, 22:05
by Beakster
Hi,
I was about to do a gearbox oil change. Took the filler plug out and then went to remove the drain plug and saw it had been welded. When I saw that I decided to stop and ask for some advice as I'm not entirely sure what's happened here and I'll need to be able to get it back in so I can use the van.
Anyone seen this before? My guess is that the hex socket plug rounded so they welded a bolt head onto it? I'm hoping they haven't welded it to the box. If i remove this with a socket and then have a new drain plug on hand think I'll have any issues?
Thanks
Re: Removing a welded drain plug
Posted: 06 May 2026, 07:06
by davidoft1
Unlikely that the mild steel plug is welds to
The ally gearbox case, more likely they just welded a bolt into it, undoing it is the only way to find out
Re: Removing a welded drain plug
Posted: 06 May 2026, 07:26
by MarkHughes
I have welded to sump plugs in the past when they are seized and needed heat and/or another bolt welding on for turning them, It looks like this one has been heated in the past to unseize it. It probably isn't welded to the aluminium.
Job 1, Order a new sump nut. Then when you put the new one in, Torque it correctly with a new washer.
Re: Removing a welded drain plug
Posted: 06 May 2026, 11:34
by jrt
Does it leak, I can’t tell by properly by the photo?
Obviously some previous owner repair of some sort in the past. You could always use a simple pump to remove the old oil while you see how lucky you feel before removing it.
David.
Re: Removing a welded drain plug
Posted: 06 May 2026, 12:27
by silverbullet
Ah yes. Welding aluminium to steel. Like gluing chalk to a slice of banana...
Re: Removing a welded drain plug
Posted: 06 May 2026, 12:29
by silverbullet
MarkHughes wrote: ↑06 May 2026, 07:26
Job 1, Order a new sump nut. Then when you put the new one in, Torque it correctly with a new washer.
Its a taper thread plug on the transaxle. No washer.
Re: Removing a welded drain plug
Posted: 06 May 2026, 18:33
by MarkHughes
silverbullet wrote: ↑06 May 2026, 12:29
MarkHughes wrote: ↑06 May 2026, 07:26
Job 1, Order a new sump nut. Then when you put the new one in, Torque it correctly with a new washer.
Its a taper thread plug on the transaxle. No washer.
Ah, So isn't this one supposed to be a 17mm or so hex ? I guess they welded the bolt in due to rounding it or not having the tool.
Re: Removing a welded drain plug
Posted: 07 May 2026, 06:38
by silverbullet