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Grey996
Spa-Francorchamps


Joined: 24 Jan 2017
Posts: 346
Location: Sheffield


PostPosted: Sat Nov 16, 2019 7:45 pm    Post subject: Gearbox filler plug rounded, any ideas? Reply with quote

Luckily I tried to remove the filler plug before draining the box only to find the hex bolt is rounded off!

Access is very tight so I can’t get a grip on the plug or any space to try and hit a larger key in there.

Other than dropping the gearbox does anyone have any other ideas?
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Alex
Le Mans
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Joined: 06 Mar 2014
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Location: The Ribble Valley, Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Sat Nov 16, 2019 7:55 pm    Post subject: Reply with quote

Saw a slot in it with 2 hacksaw blades in your hacksaw (so double width). Then get a steel plate the width of the saw cut, line it up in the slot lengthways and turn.
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deMort
Dijon


Joined: 21 Mar 2015
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PostPosted: Sat Nov 16, 2019 8:05 pm    Post subject: Reply with quote

Agree

might be the best solution if you can't hammer a spline tool into it .
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Grey996
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Joined: 24 Jan 2017
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PostPosted: Sat Nov 16, 2019 8:23 pm    Post subject: Reply with quote

Thanks, I’ll have to have a go in the morning but I don’t think I can get a hack saw in there.
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Alex
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Joined: 06 Mar 2014
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2000 Porsche 996 Carrera 4

PostPosted: Sat Nov 16, 2019 8:36 pm    Post subject: Reply with quote

You can also just cut a slot just using the bade then get a screwdriver (use like a chisel) in the slot and tap it round with a hammer.
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911munKy
Montreal


Joined: 26 Nov 2014
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PostPosted: Sun Nov 17, 2019 9:01 am    Post subject: Reply with quote

Hammer a smaller A/F socket onto it.
Hacksaw 1/3 off the side of the bolt and get an adjustable on it - need to cut in the right place to ensure you get enough movement to undo.
Buy an Irwin grip nut set?
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infrasilver
Fast & Furious
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Joined: 04 Oct 2010
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Location: East Midlands

2001 Porsche 996 Targa

PostPosted: Sun Nov 17, 2019 3:06 pm    Post subject: Reply with quote

My gearbox drain plug rounded on the 944 when I changed the oil last week, got some heat into the casing before hammering a large Torx into it and it undid easily then.
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Grey996
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Joined: 24 Jan 2017
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Location: Sheffield


PostPosted: Sun Nov 17, 2019 3:15 pm    Post subject: Reply with quote

Thanks all, Alex’s slot for the chisel worked a treat.

Issue I’ve got now is that there’s something blocking the whole on the inside. It looks like another sort of internal cap where the rod on the end of the filler plug must slot in but I can’t get any oil in with this there. I can move it slightly but I don't want it to drop into the box.

Also none of the replacement plugs I’ve seen are like this so I’m not sure what’s going on?

New Top Gear Cats have gone on well and look great though.

Thanks
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Grey996
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PostPosted: Sun Nov 17, 2019 3:17 pm    Post subject: Reply with quote

Filler plug
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Grey996
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PostPosted: Sun Nov 17, 2019 3:49 pm    Post subject: Reply with quote

Just realised my mistake, that’s not the filler plug is it!

I’m off to quickly put it back in!
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Grey996
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PostPosted: Sun Nov 17, 2019 4:58 pm    Post subject: Reply with quote

Slightly embarrassing but all sorted now. Nothing like turning a 20 minute easy job into a hour long nightmare!

Out of interest, what is the other plug for?
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deMort
Dijon


Joined: 21 Mar 2015
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PostPosted: Sun Nov 17, 2019 5:26 pm    Post subject: Reply with quote

That's not the filler plug as you have found out .. i believe that's a selector shaft retaining bolt .. make sure with it refitted you can get all gears please before starting it up .
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Grey996
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Joined: 24 Jan 2017
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PostPosted: Sun Nov 17, 2019 5:40 pm    Post subject: Reply with quote

Thanks, yes luckily all the gears seem to be ok!

The head on the plug wasn’t actually a hex after all but looked to be an 8 or so fitting. I wasn’t able to get it totally tight so could do with buying the proper tool if you know which what it is and what size?

Thanks
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deMort
Dijon


Joined: 21 Mar 2015
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PostPosted: Sun Nov 17, 2019 6:38 pm    Post subject: Reply with quote

I would have thought it was an 8mm allen key or hex bolt as most of them are on porsche boxes .. i can't quite see from the angle of the bolt though.

Best guess is it's no.19 on the above image from pet.

If it helps then even us mechanics don't always know the right bung to remove and have to look up instructions .
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My Daughter's Crowdfunding has hit the target .

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Grey996
Spa-Francorchamps


Joined: 24 Jan 2017
Posts: 346
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PostPosted: Sun Nov 17, 2019 6:56 pm    Post subject: Reply with quote

Thanks deMort, I do normally have to look things up but didn’t bother with such an easy job! it does look exactly like a filler plug though, if only I’d watched the YouTube video beforehand bonk

It’s too big for an 8mm and too small for a 10mm so that leaves a 9mm. An unusual size but I suppose it could be?
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Last edited by Grey996 on Sun Nov 17, 2019 7:43 pm; edited 1 time in total
 
  
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deMort
Dijon


Joined: 21 Mar 2015
Posts: 7593
Location: Brighton


PostPosted: Sun Nov 17, 2019 7:17 pm    Post subject: Reply with quote

Lets just say plugs are normally an 8mm but this is one i've never removed before so cant say for certain .

It happens .. best if i don't list the mistakes i've made over the years !!
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My Daughter's Crowdfunding has hit the target .

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Now At An Indy.
 
  
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wasz
Sepang


Joined: 28 Dec 2012
Posts: 2998


1999 Porsche 996 Carrera 2

PostPosted: Mon Nov 18, 2019 11:36 am    Post subject: Reply with quote

You can get some mole grips or stilsons on the outside of the plug to tighten it back up. Or go buy a new one.....

Thats how I got my old filler plug out as it rounded. Likely never been out.

New one from OPC was shiny blue alloy.

always take the fill plug out before the drain...
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Grey996
Spa-Francorchamps


Joined: 24 Jan 2017
Posts: 346
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PostPosted: Wed Nov 20, 2019 5:33 pm    Post subject: Reply with quote

It’s not a 9mm so I’m stuck! Are there any other socket types that Porsche use?
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Last edited by Grey996 on Wed Nov 20, 2019 6:40 pm; edited 1 time in total
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7333
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed Nov 20, 2019 5:51 pm    Post subject: Reply with quote

I'll check on a spare gearbox for you tomorrow if you like.

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kurlykris
Magny-Cours


Joined: 30 Jun 2014
Posts: 2576
Location: Warwickshire


PostPosted: Wed Nov 20, 2019 5:58 pm    Post subject: Reply with quote

As an engineer, the first things I would try next, an Imperial allen key to see if you get a better fit.
A nice brand new pair of mole grips, you can get a set of 3 sizes from screwfix which are fairly good quality, I bought some a few weeks ago to do a particular job at work ( I have never owned any before, but these were my only option with the job in hand ) item no 4091V. £8.99
Try some shim steel / feeler gauge down the side of your 8mm allen key and bend it 90 degrees over the end of the allen key so that the key pushes it down the hole as you insert it.

Best of luck Thumb
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