So I put my car G on a lift today to change my gear oil for trans and diff. I changed the diff and now onto the trans. And what do I see? A rounded out filler plug....I didnt drain my trans yet (thank god) but whats the best way for me to get the filler plug out because I tried couple ways even trying to form it into a hex. Didn't work...spread some knowledge please!

 

Easy out would work the best.
If not you can always use a air grinder with a small cut off wheel and notch it to fit a flat blade screw driver.

Or jb weld a allen in the hole and wait for it to set up and pray it holds long enough to remove the cap.

 

Take a die grinder to it and grind a slot right in the middle of it to get a decent size flat bladed screwdriver in there to back it off. If you need more leverage, use a wrench on the screwdriver to help back it out.

 

yeh i thought about that also. i dont want to grind my housing thats why. ill wait till i get a new fill plug then do it i guess. any other suggestions? i tried vicing it also..no luck that thing is SEIZED in there..and its in a pretty tight area also..

 

Trying tapping the bolt pretty good with a hammer and punch for a bit, then try backing it out with what ever you have

 

Vice Grips with a length of pipe for leverage should get it loose. Wonder what dumb azz put it on that tight? Snug is tight enough....
Gary

 

tried that..didnt work =[ and i was mad as hell cuz i bought this car used..is there another hole i can fill it at though?

 

this is easy. get a small torch from a hardware store. heat up the pan. about an inch away from the plug, all the way around the plug. this will cause the metal to expand. which will loosen the plug quite a bit. then take whatever you can get ahold of it with and twist it out

 

its the tranny..its aluminum...its a manual

 

I hope you tried a 6 point socket and not a 12 point

 

Make sure you try to remove the bolt when the car is fully warmed up. Bolts are generally harder to get out when everything is cold.... the same goes for oil filters, etc.

If you have an impact wrench, try using that to get out the bolt.... those things work great for getting out bolts that are in sorry shape. That worked for me on my Tacoma when I bought it used and the front diff. drain plug was stripped by the previous owner.

Worse comes to worst, get ahold of a welder and weld a bolt into the filler plug, then back out the bolt, which will remove the filler plug that it is welded to as well.. then replace it with a new one.

 

when i saw it it was originally a torx. then i turned it into a hex after it was already rounded it. then it still didnt break loose. so im going to try to back it out. if it doesnt work i guess i have to welf a bolt head or nut on it to back it out.

 

I was going to say vise grips but saw that you already tried it. Use a small monkey wrench. It will give you all the leverage and grip you need. It was made for surfaces like a rounded out bolt.

 

yeh but if u ever look at the filler plug its so thin that its hard to get a good grip on it.

 

You might try a diamond point chisel (refers to the shape of the point, not the cutting edge material) align the tool so that when you strike the point digs in and applies rotational force to unscrew. I would give the plug a good heating beforehand and cool with penetrating oil, also heating the aluminum housing just before the hammering starts might help, taking advantage of differential expansion (warm hole, cool plug). If it comes down to welding a bolt to it, I would disconnect the battery beforehand. I have heard of arc-welders doing strange things to electrical systems.