Help Gearbox filler plug removal!!

[Firept]

I'd like to get hold of the person who's wound this filler plug in and attack his vitals with water pump pliers squeezing very hard and and rotating slowly!!!

OK any ideas please the gearbox is in situ the square end has been rounded off (before I started) it does still have a semblance of sides to it. I have tried tonight with a Snap on bolt remover, the type with a hardened reversed thread inside a socket, this gripped very well great I thought but then it gave way and it’s just removed some more of the stub.
I could probably just about get a welder on to it with a nut but its so tight to the tunnel cover. Possibly drill a hole through the stub and fit a bar? but knowing my luck it will snap off and I'd still have the plug left in. Any great ideas gratefully appreciated...no I'm not taking the gearbox out.

Paul.

[stagmuffin]

i had to weld a nut on mine i tig welded it ,itried to move it as soon as i welded it and it came out easy .so try heat either indirect by holding a cloth soaked in boiling water (gloves) or direct with a blowlamp(look out for the fuel line) around the area it may go after a short while.got to be worth a shot before anything more drastic.

[nib]

I had a similar problem on mine,in the end the molegrips came to the rescue,a decent set of molegrips are a must,I think mine are American made called Vicegrip.
Mark

[Firept]

Thanks guys for the fast response I think its coming down to the application of heat, I've just ordered a stud extractor, the snail cam type. I just hope there is enough space to get it on the end of the plug.
Why did Triumph go to all the trouble of cutting an access hole in the transmission tunnel .....but in the wrong place!!

Paul.

[Andy Rundell]

I'd use a long pair of Stilsons as their grip increases as more pressure is applied - personally i'd avoid molegrips.

To be honest i'm surprised it didn't come off with the SnapOn bolt/stud remover - they are usually excellent

.............Andy

[Greenstag]

Stilsons did it for me after a long soaking of Plus Gas...think I even made up a little reservoir with blue tack and let it soak in

Good luck...Dave

[Rubce]

After leaving to soak with penetrating oil, hammer a socket onto it and then using a wrecking bar. Worked a treat on my diff.

Bruce

[DJT]

Why did Triumph go to all the trouble of cutting an access hole in the transmission tunnel .....but in the wrong place!!

The access panel is for the inhibitor switch on automatic gearboxes.............

I have a selection of Bahco adjustable spanners. I always find that the 18" chappie manages to shift most things, including the gearbox filler plug.

[Firept]

Thanks for all the tips and tricks.
I should be able to get on to it tomorrow PM and try some of this out I will let you know what worked.

Paul.

[Stagdad]

As long as you can get stilsons in there i would be suprised if they dont do the trick.

Cheers Steve

[marshman]

Thanks for all the tips and tricks.
I should be able to get on to it tomorrow PM and try some of this out I will let you know what worked.

Paul.

Paul,
As the filler plug is already chewed up don't mess around "trying" things. As you found with the bolt remover you can just end up shaving more precious bits of metel off. You need to go in for the kill. My approach would be to give it an over night soak in Plus gas penetrating fluid, forget WD40 or similar they are useless for this task (in my opinion), then when you are ready to have a go gently warm up the casing around the filler plug with a blow lamp (watch the flame doesn't set fire to anything, or use a hot air gun. Don't spend too long as the heat will flow into the plug. Then get your stilsons - nothing else will do - make sure they have a good bite then undo it - use an extension pole over the handle if you need to. It will shift it even if there is next to nothing to hold onto. You do need to ensure the stilsons have good teeth and are adjusted up correctly. And, not being funny, but if you are not sure what stilons are then ask and one of us can post a picture because none of the pretenders such as mole grips, or quik wrenches or similar will do the job. With stilsons the harder you pull the harder they grip.

good luck

Roger

[peter f]

Hi Paul,
I fitted a 3.45 : 1 diff which was good, but had been in the back of a shed for a fair while.
I decided to remove the filler plug to check the oil, and had all the problems you have had in trying to remove it - even though it was on the bench. I took it to an "old school" engineer, and we tried everything he had, to no avail.
We ended up cutting off what was left of the plug head, and drilled it out carefully, using bigger and bigger drills.
It resisted right up until there was only a sliver of threads left inside the hole, which had to be drifted into the centre of the hole to remove them.


What a trauma, and just as bad was cleaning out all the swarf from the inside of the diff.
Don't you just love a challenge!!
good luck bud,
Peter f

[Cliff Perry]

Paul

Try Easy Out Sockets,with a left handed thread,specially designed for rounded bolts,they worked for me?

[v8wgm]

I don't have the correct square spanner for the job.

However if you put a 19/32" socket in reverse onto your 1/2" drive ratchet, you have a perfect 1/2" 4 sided spanner!

I used to try & use two 1/2" spanners side by side but they could still round the corners.

[Firept]

Roger.
Thanks yes I do know what Stillsons are I have a couple of different sizes, I agree mole grips or similar are no good for "mans" work!
The main problem is that you cant get a good straight pull on the plug as the web just beneath the plug holds off the spanner / device/Stillsons at an angle and I think that's half of the problem. Like peter if it does not move then I could drill it out re-tap it and screw in a set screw, lock it off and see if that will do it.
Welding a nut on to the stub also sounds good especially after I have cut the hole in the tunnel cover the heat may just break the seal.
Last resort will be to drill it out completely. I was thinking of may be some low pressure air applied via the drain hole so that any swarf will be blown out of the drill hole (with luck) as it breaks through.
What is really more annoying is the oil I drained out was clean!! Its a one owner car with all its documents and original bill of sale but has not been on the road since 2000.
Thanks to you all just what the forum is all about.
Paul