R380 stripped filler plug

OneZero · Jan 25, 2020

I've had my 1995 Defender 110 (300tdi) for about 9 months and realized I should probably check the gearbox oil. However, the T55 plug was extremely tight and I have stripped it (in quite an impressive manner). I have tried bolt extractors as well as a punch to pound it counter-clockwise with no luck. The pictures are below. Does anyone have any ideas? I've scoured the internet and haven't found anything quite like my situation.

trigga72 · Jan 25, 2020

Weld a key onto the plug ,let it cool then undo
You're welcome

OneZero · Jan 25, 2020

If only I had a welder...

trigga72 · Jan 25, 2020

OneZero said:
If only I had a welder...

Ah, there's your problem !
If you haven't drained the oil, just get it to a workshop ideally with a ting welder and get them to weld a key or a bolt onto it

lynall · Jan 25, 2020

I reckon a quality pipe wrench will get a grip on that, not old and worn with rounded jaw edges, but quality with new sharp edges on the jaws.

trigga72 · Jan 25, 2020

You cou

lynall said:
I reckon a quality pipe wrench will get a grip on that, not old and worn with rounded jaw edges, but quality with new sharp edges on the jaws.

I was thinking similar, the shoulders of the stillsons might get in the way though. Or did you mean the Plumming sliding types ? Might be worth trying some large mole grips?

Disco1BFG · Jan 25, 2020

trigga72 said:
Weld a key onto the plug ,let it cool then undo
You're welcome

+1 - will probably find some one has used loctite on it

When you get it out, fit a plug with a hex head

OneZero · Jan 25, 2020

You guys are awesome and I appreciate the recommendations! I have a plug from an LT77 ready to go once I get this bastard out. I have literally tried everything in my tools inventory with no luck so I'll probably take it to the garage on Monday and have them weld a bolt to it. I've spent two days trying to get it loose so I think I'll just drink a beer and start browsing the internet for a welder!

trigga72 · Jan 25, 2020

OneZero said:
You guys are awesome and I appreciate the recommendations! I have a plug from an LT77 ready to go once I get this bastard out. I have literally tried everything in my tools inventory with no luck so I'll probably take it to the garage on Monday and have them weld a bolt to it. I've spent two days trying to get it loose so I think I'll just drink a beer and start browsing the internet for a welder!

That's the spirit !
At least you didn't take the drain out first !

OneZero · Jan 25, 2020

trigga72 said:
At least you didn't take the drain out first !

I'm glad I didn't drain it as well! That was another piece of valuable advice that I picked up from this forum!

lynall · Jan 25, 2020

trigga72 said:
You cou

I was thinking similar, the shoulders of the stillsons might get in the way though. Or did you mean the Plumming sliding types ? Might be worth trying some large mole grips?

Moles wont work they will just chew it up more, sliding type might do it again need to be be with good square jaw edges and a quality make, but I am pretty certain a proper pipe wrench will get it.

trigga72 · Jan 25, 2020

lynall said:
Moles wont work they will just chew it up more, sliding type might do it again need to be bew with good square jaw edges and a quality make, but I am pretty certain proper pipe wrench will get it.

Worth a try

lynall · Jan 25, 2020

trigga72 said:
Worth a try

Moles have two uses,1 for holding something whilst you weld it and 2 for holding something whilst you weld it

trigga72 · Jan 25, 2020

lynall said:
Moles have two uses,1 for holding something whilst you weld it and 2 for holding something whilst you weld it

That's true , but they have been known to get people out of the ****e now and again

gstuart · Jan 25, 2020

Hiya

for what it’s worth when I’ve had issue like this I’ve used a Dremel, cut in a slot then taped it round

alas though looking at that getting something welded onto it sounds favourable

if I may also make sure u disconnect ur alternator and battery before the welder is used

fingers crossed it comes out with the least amount of agro

steve2286w · Jan 25, 2020

Small chisel and tap it round with hammer, maybe a bit of heat first on the ally casing

Henry_b · Jan 25, 2020

Chisel and a 'ammer.

Don't tighten the **** out of the new one..

Absolutely no need.

Really ****es me off when i get one in for a service and the previous mechie/DIYER cranked it up like a f"ucking headbolt.

OneZero · Jan 25, 2020

I've tried the chisel and hammer quite a bit but the plug won't move...it just deforms the soft metal which is evident in the picture. I have all day tomorrow to keep trying though!

gstuart · Jan 25, 2020

Henry_b said:
Chisel and a 'ammer.

Don't tighten the **** out of the new one..

Absolutely no need.

Really ****es me off when i get one in for a service and the previous mechie/DIYER cranked it up like a f"ucking headbolt.

plus 1, before I’ve used a dremel on other filler plugs , cut a slot then knocked it round , along with some gentle heat

also reminds me I need to get my auto filler out on the ZF6, don’t think it’s been removed for a long time, will use the dremel first to clean it up then see if it moves, new filler plug is the flange type , shame the drain plug is plastic

Henry_b · Jan 25, 2020

gstuart said:
plus 1, before I’ve used a dremel on other filler plugs , cut a slot then knocked it round , along with some gentle heat

also reminds me I need to get my auto filler out on the ZF6, don’t think it’s been removed for a long time, will use the dremel first to clean it up then see if it moves, new filler plug is the flange type , shame the drain plug is plastic

View attachment 198930

Stick an Alan in there G

And give it a good whack with a big 'ammer

Shock it loose!!

constant pressure will strip it..

R380 stripped filler plug

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