gear box refill plug stuck!!

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disco 1 harrogate

Member
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87
Location
Harrogate , North Yorkshire, Uk
Morning peeps,
I'm trying to change the gear box oil on my disc 1 .I've gone with the golden rule " make sure the the refill plug comes out before you empty it !". ( good job I did). The refill plug is a star shaped one and looks like the last person to change the oil has " rounded"the star shape quite a lot . I've tried to loosen it ( won't budge)..I don't want to do anymore damage. Anyone any ideas ????? Thinking about taking it to Kwik fit , as they must come across this everyday .
Thanks in advance for any advice.
 
Its hard to know how bad it it without seeing it but if you can still get a good grip with the right tool then you shoukd be able to get it out.

Try giving it a good soaking with penetrating oil and a few sharp blows with a hammer. This should help loosen it.

Mark
 
I find when trying to remove a stuck fastening that it's better and less potentially damaging if you use a series of light taps, rather than belting it and damaging threads or the sump.

The way I would do it is this:

1. Assemble your socket driver, bit holder and T55 torx bit and place in the fill plug;

2. Give the socket driver a series of regular taps - perhaps 50 to 100 - and then remove the plug. Buy a new plug !!!!!


Dave
 
does that realy work giveing it loads of light taps like that?? ive always just put pressure on the nut or bolt and then got some one to whack it hard while your turning
 
adam300tdi said:
Does that really work giving it loads of light taps like that?? I've always just put pressure on the nut or bolt and then got some one to whack it hard while your turning
Click to expand...

It most certainly does! It's especially useful if you are working on something that is potentially 'delicate'.

Dave
 
what does it do then just shock it till it loose??.only reason i use the method ov whackin it was bcoz as im sure ppl with a new disco or rangie will no the lockin wheel nuts r ****.and once when 1 was stuck on i saw some 1 smack it with a slege hammer nd then it came off by hand,
 
Also a curve ball don't be afraid to drill a hole in the side of you're transmission tunnel to access the work better if neccesary, access holes like that can be handy in future for refilling oil etc :)
 
If you're going to do as my noisy says, mark it with something from the insie of the transmission tunnel so you know where to drill - if there's room swing a small hammer from the filler bung to the tunnel to dent it, if not, use a pry bar or similar to dent it slightly. That way you can pull the carpet back, locate the dent, centerpunch it and drill through, knowing you're in the right place. Step/Cone drills are probably the best things for the job and see if you can get a rubber bung of the correct diameter before you start...
 
Huzzar!!!!!.....problem resolved...bought t55 from halfords £7.99 ...wd40 ( a good spray) ....tried the 100 light tap method X2 , no joy...more Wd40...no joy......tried hammering it ( slightly harder taps )...no joy .....in the end I got an old broom handle(!) Chopped 18inchs off it ...popped the end of my socket bar in it ( which gave me more leverage) .....and it popped ....PLEASE NOTE: will be taking it on Dragons den ......lol....." Broomie- handle-socket-wrench™"
Thanks again for everyone's advice .
 
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