Have previously posted on this issue and still not resolved! Determined to overcome this, so spent a lot of time today taking off the transmission tunnel housing and the umpteen rusted in screws that hold it, Can now get easy access to the plug. T55 socket does not grip, plug rounded internally. Tried penetrating oil, heat and most recently cold steel chisel. Not budged a mm!
Looking online for the best tool to get this plug out. Irwin bolt extractors came to mind, but they require a fair bit of metal standing proud to get a grip. The filler plug has only a couple of mill. Glow plug extractors seem a possible option but has anyone out there got a better solution/tool for the job?

Speak to jamesmartin he will know

you could give the bolt extractors a go, if there's not enough sticking out, then the only option would be drilling it I guess.....unless there's enough to weld a nut to.

gse1986 said:

you could give the bolt extractors a go, if there's not enough sticking out, then the only option would be drilling it I guess.....unless there's enough to weld a nut to.

Click to expand...

By the sound of it the welding may well be your best option
Drilling it would open up a massive can of worms

weld in the t55 bit

I would go with the welding of a nut. By far your safest option. You do not want to start drilling this as drewster has already mentioned.

And get a new plug before you start

The problem is caused by disimilar metals in close contact.
Get a new plug BEFORE you start.
As the existing plug is buggered then you dont need to worry about being delicate with it. Before banging anything into the old plug get some heat on it. Use a blowlamp with something like MAPP gas as an acetylene torch will be too hot and you risk melting the surrounding allow of the gaerbox casing. Find something steel that is a tight fit in the rounded plug (you will need a hammer to drive it in). Drive in whatever you have found and see if it will free the plug. Sometimes slightly tightening a stuck bolt will help to loosen things up. (sounds daft but it works). Obviously dont screw the plug all the way into the box.
If it still wont budge then the only option I can see is to drill a hole through the middle of the plug and use the reverse thread extractors with heat and penetrating oil.
Good luck.