engine and drivetrain SOT: How to remove and ruined tranny fill plug

[Grover]

Hi guys. On our Lemons car we have a transmission fill bolt which has been absolutely destroyed. It does not have a recessed allen hole, rather it is/was just a more traditional 17mm (I think) bolt. It has obviously been abused grossly on numerous occasions and it is now impossible to get a good purchase on it, not to mention the fact it is on there incredibly tight. I've tried a heat gun, breaker bar on vice grips, etc... Have made ZERO impact. Any suggestions on getting the sucker out of there?

[Husker2002]

I am guessing from you description that the external "head" of the bolt is rounded off or destroyed. Given that, I have had luck using a pipe wrench as the aggressive teeth really bite into the metal and gets tighter as pressure is applied. Might want to try "shocking" the plug by smacking the wrench handle with a dead blow hammer. Only do this if you can't break it loose by hand. Be careful, you could conceivably crack the pan.

I had a friend that had one of the internal hex head plugs stripped. I was able to get it out using an EZ out. I think most problems with stripped heads, internal or external, are caused by owners not using the correct size tools. Nothing ruins, rounds off fasteners faster than a tool that "fits", but not the actual correct size.

Best of luck getting that plug off !!!

[ray_]

Weld a nut to it.

;-)

Ray

[jdm1602]

I've had good luck with these reverse thread thingies. Depends on what's left of the plug in this case.

[Mike Self]

Sears has 'em and they're really handy for totally boogered up bolt & nut heads. Always take mine to salvage yards "just in case."

mike

[tim385]

+1 weld a nut to it , wheel nuts work well a good mig weld inside the nut , plus the heat from welding helps as well .

[BDB]

been there, done that: +2 on welding a nut to it

[Davo]

I just weld an old cut off half inch extension I have to them and take them out with my impact gun. A nut would work as well.

[Tiger75]

Ray,

are you volunteering to be the nut?

i'll vouch for you.