Hey ya'll,

Finally getting my car back together however I have ran into a problem.

The fill plug for my t5 transmission is super jacked up.

What are some ideas on going about getting this out? I've tried a heat gun and some vice grips but I am having some trouble.

Any other ideas?

Thanks!

 

If you have the tools and ability, weld a nut on the end and use a socket or wrench.. If you have to drill it out, "Left Hand" drill bits are much better than standard, "Right Hand" bits. Good Luck !

 

Thanks for the tip! Unfortunately I don't have the tools to weld something on, I was thinking about drilling it out, but I am a bit concerned about getting flakes into the case.

Is there something like superglue or that putty that hardens I could use in place of welding? This is one of the the last things I need to do before doing a test drive of some of my new parts, so I'd like to take care of it.

 

I can not imagine an adhesive stronger than the bond, between the threads on the drain plug and the threads in the hole. What kind of plug are you dealing with? NPT (National Pipe Thread) or straight thread plug with a washer-head and sealing washer?

 

Uhhh, it looks like this, NPT.


The inside has been essentially rounded.

 

Is the trans empty of fluid? Or do you need to drain it. If it is already empty, just fill though the shifter and you won't ever have to worry about that plug. It is has fluid, you'll have to get an easy out in there. Welding a threaded stud into it is also an option if you have that capability.

 

There is fluid inside, I'm just positive it's a bit low. I can't tell how much I have.

I'm gonna wail on it a bit more when I get home later before finishing up my new spark plug wires.

 

The tool you need is known as a Multi-Spline Screw Extractor. I would probably try it without heat first, and if that doesn't work, add heat.

 

Out of curiosity what square/size drive tool are we using in that square hole to remove that drain plug. I got a few T5s under the house but too lazy to go into the crawl space to look at what you're dealing with.
Suppose the right tool may have solve some of the problems...
Removing a similar plug on the cylinder head, I took a grinder to a bolt and ground it to a square taper. Couple of taps with a hammer before hitting it with impact gun got it out with no fuss...sorry I know, this might work before it was jacked up

 

I purchased a kit of these, they look handy, will try it out later today.

Thanks for the tip.

 

I think I tried to use just a plain 3/8 wrench in there. However I don't think I was seated all the way during the first few attempts. It's in there unreasonably tight. I heard some people put Teflon around the threads in order to have an easier time getting it out? Might do this with my new bolts when I get this out.

 

Get a ratchet you don't care about, whatever size it needs to be to fit in the square hole, and a really long pipe. Like, the 4' handle for a floor jack, long.

Use the leverage and it'll break loose.
I wouldn't put teflon tape on it, i'd just wire brush it really good and wipe it with oil before putting it back. Whoever put it in there probably just cranked on it.

 

There's no way I'm putting the old one back in when I get it out lol. I got replacements already.

Anyone know the torque spec for these?

 

I always just snug it, not really tight at all compared to other bolts. Similar to spark plugs in aluminum heads, if that helps lol

 

Wellp, I used the tool, got a couple good pulls on it, potentially even saw the bolt move a hair, though now I'm doubting myself.

I'm angry and defeated. I suppose the next step is to find someone with a welder cause I'm at a loss.

One of the primary issues is that I cant really fit a hammer between the space to properly tap it in, though id say I got it pretty tight maybe 5 times and I'm all out of juice.

I don't even know how its possible to be in there so tight.

Now the hole is rounded. Here are some pics for fun.

 

That's messed up with a capital F.

Looks like time for a right-angle drill with LOTS of grease on it, and drill it out to about ½", and use one of the square type bolt extractors on it. You might need to wizz-wheel the drill bits and bolt extractor off real short.

It's not really all that tight; it just goes into aluminum after all. Just a pipe plug. Problem is, once that square drive (which is some oddball size, don't ask me why some numbnutz thought THAT was A Good Idea) gets damaged, it's all over with.

Get a brass one at the hardware store that has a drive that sticks out instead of having a socket of any kind. Most commonly they are square but there are hex-drive ½" pipe plugs too. Use Teflon tape or Teflon pipe sealer on it. It's not necessary to torque it to more than 15 ft-lbs or so.

 

Jeez 😳😳

Have you tried lowering the crossmember and seeing if you can tilt the motor enough to give you more room?

 

I'd try drilling it out and going up a size on the extractor. If it gets enough purchase, it'll bust loose. Add heat to the equation. Alternatively, you could cut a notch in it and try to chisel shock it free, but there's potential to damage the case if you miss.

Maybe use a left hand drill bit so if it augers you'll either break the seal or your wrist.

 

Are you able to get a pipe wrench on it?

 

get a faucet seat wrench, trim till its snug.