gearbox drain plug

[collyb]

anybody any ideas on how to remove a gearbox drain plug thats,,,rung,,and looks lik the previous owner mauled it with every device going..lol

[Damo77]

The way I've done it in the past was to sacrifice a slightly larger torx bit/socket and hammered it into place so that the teeth bite into the metalwork. Then try to wind it off.
Failing that if the edge of the plug was thick enough and proud enough, then I would file opposite edges flat to get an open ended spanner on it.
If you've got acess to a welder then you could always tack weld another nut onto the surface and try crack it open that way

Good luck though hope it comes out without too much bother

[xf8u39]

I had a similar issue when I was changing the engine and box oil one afternoon. The sump plug appeared to be made of low quality material and rounded off in no time, even with a hexagon socket on it. I ended up welding a socket onto it. That did the job.
When it came to the box drain plug it was a different matter. It is a Torx fittting, which too quickly rounded off. I had to chisel that one off, having first made sure I had removed the filler plug. I filled it with 2.5 liters of 75/90 oil and seems to be better than the red stuff that came out.
Job done

[tyler boy]

what mileage should the box oil be changed anybody

[collyb]

ive tried tapping it off with a chisel and a hammer,,,but no joy,,,the guy who had it before me totally rung the torx hole in the drain plug,,,,i think i may have to weld sumthing t it and try that way