Chaps, further to this thread http://www.landyzone.co.uk/lz/f8/my...hat-size-hex-key-do-i-need-top-up-181642.html the other day, I've been attempting to remove the gearbox sump plug (02 TD5 auto) this morning without much luck. Initially managed to get the plug moving without too much hassle, kept turning, and turning, and turning.... It's not going anywhere. I tried to tighten it up again and the same; it's just turning. I tried to lever it out with a screwdriver but it's stuck fast in there. Any thoughts on why it's done this and a possible solution?

Many thanks

Sound to me like you've stripped the thread. Have a read on www.discovery2.co.uk / Automatic Gearbox Oil and Filter Change and it'll show you how to remove the sump.

If you have stripped it, then a second hand sump would be a good place to start. There's plenty of people on here who are breaking Land Rovers for spares, so I'm sure if you ask nicely someone will even make sure the plugs move before they send you a replacement.

I may be wrong but sounds to like the threads have gone, only way I can think of to get it out now is to drill it out, going to get messy but drill through but leave drill in the hole and take power unit off the drill, at least that way it won’t gush out until you remove the drill, once oils out make hole bigger and then crack the plug and it should drop out. Then you can see if the sump has threads left if not you can cut new threads.

Thanks for the replies. I suspected this might be the case! I did a search on here and someone suggested it was possible to top up the oil through the oil cooler pipes. Seems logical. The oil "out" end of the oil cooler seems accessible enough. Is this a good idea, or am I better off tackling the plug issue?