Gearbox Drain Plug Damaged

[sturb25]

Last time the mechanic tried to change my gearbox oil they damaged the head of the drain plug severly by using the incorrect tool ( A half inch square socket drive ).

I bought the correct 13mm square drive drain plug tool that i thought might be able to get it out cause it still fitted in the hole tightly. I tried to un do it with both my hands and my girlfriends legs on a power bar couldnt even budge it we had that much force on the bar that the knuckle was flexing and because weve put so much force on it it has further damaged the drain plug.

I dont know what to do, im running out of options.

The thing that pisses me off is you would think that a reputable mechanic shop that services skylines all the time would have the correct drain plug tool or if they new they couldnt get it undone they wouldnt totally #@%& it.

Im just really pissed off, Can anybody offer any solutions. Its got to come out.

[pipster11]

I had to put a sleeve if pipe over my breaker bar to get the transfer case filler bolts out and even still it was hard work

I thought I was gonna break the bar or pull the gearbox out

[Daleo]

The steel plugs often bind in the aluminum housing of the box due to electrolysis. If you can give the plug a sharp hit with a hammer, this will often free it. Alternatively, a can of freeze spray (CRC make it) will shrink the plug & break the bond.

[sturb25]

I had to put a sleeve if pipe over my breaker bar to get the transfer case filler bolts out and even still it was hard work

I thought I was gonna break the bar or pull the gearbox out

Yep i had that thought this morning as my last resort, went to bunnings bought a steel square section bar about 1200 long and i got it out, it was still bloody hard but its out and im smileing yay

[pipster11]

Yeah, they use a tapered thread and sealant goo so it's hard to get out

[czeno]

Seems I left the best till last, done the final drive oil changes except the transfer case a while back, fairly straight forward getting bungs undone. Last weekend put the stag on stands & tried loosening the transfer case filler plug, I've now got a small pile of broken tools & a sore arm and the plug is still in there. Good news is the square hole of the plug is still ok, shame it's only a 10mm square.

I broke an SK 1/2" to 3/8" adaptor socket then I welded an old 3/8" rachet solid - broke the square drive off & bent the handle. Next up cut & filed a high tensile bolt to a 10mm square as a key, quite good because it capped the plug & I could give plenty of taps with a hammer to help loosen it, all strength maxxed out pulling on a ring spanner - still wouldn't budge. My son climbed under the car from the other side pushed real hard with his boot on the spanner - spanner bent, plug still stuck. Not that keen on waving oxy/fuel torch under there.

Round 2 coming up another time when I have it up on stands.

[chad bob]

Last time I had a bastard bolt like this I wrapped a nylon strap round the spanner and hooked the other end to my engine crane. Had the wifey crank the crane until it let go. Almost lifted the front of the car on the spanner!

[ido09s]

I have used the oxy on really really stuck plugs before. It works a treat but due to it being alloy you obviously need to be very careful. It doesnt take much normally.