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Grey996
Spa-Francorchamps
Joined: 24 Jan 2017
Posts: 346
Location: Sheffield
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 Posted: Sat Nov 16, 2019 7:45 pm Post subject: Gearbox filler plug rounded, any ideas?
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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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2002 Porsche 996 C2
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Alex
Le Mans
Joined: 06 Mar 2014
Posts: 17144
Location: The Ribble Valley, Lancashire
2000 Porsche 996 Carrera 4
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| Posted: Sat Nov 16, 2019 7:55 pm Post subject:
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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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2000 Manual 996 C4 Arctic Silver Convertible
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deMort
Dijon
Joined: 21 Mar 2015
Posts: 7593
Location: Brighton
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| Posted: Sat Nov 16, 2019 8:05 pm Post subject:
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might be the best solution if you can't hammer a spline tool into it .
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My Daughter's Crowdfunding has hit the target .
Thank you all so Very much .
She's not going until july 2020 though .
7pm - 9pm
Now At An Indy.
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Grey996
Spa-Francorchamps
Joined: 24 Jan 2017
Posts: 346
Location: Sheffield
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| Posted: Sat Nov 16, 2019 8:23 pm Post subject:
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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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2002 Porsche 996 C2
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Alex
Le Mans
Joined: 06 Mar 2014
Posts: 17144
Location: The Ribble Valley, Lancashire
2000 Porsche 996 Carrera 4
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| Posted: Sat Nov 16, 2019 8:36 pm Post subject:
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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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2000 Manual 996 C4 Arctic Silver Convertible
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911munKy
Montreal
Joined: 26 Nov 2014
Posts: 566
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| Posted: Sun Nov 17, 2019 9:01 am Post subject:
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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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2000 C2 996
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infrasilver
Fast & Furious
Joined: 04 Oct 2010
Posts: 8507
Location: East Midlands
2001 Porsche 996 Targa
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| Posted: Sun Nov 17, 2019 3:06 pm Post subject:
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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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http://euroroadtripper.blogspot.co.uk/
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Grey996
Spa-Francorchamps
Joined: 24 Jan 2017
Posts: 346
Location: Sheffield
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| Posted: Sun Nov 17, 2019 3:15 pm Post subject:
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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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2002 Porsche 996 C2
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Grey996
Spa-Francorchamps
Joined: 24 Jan 2017
Posts: 346
Location: Sheffield
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| Posted: Sun Nov 17, 2019 3:17 pm Post subject:
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Filler plug
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2002 Porsche 996 C2
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Grey996
Spa-Francorchamps
Joined: 24 Jan 2017
Posts: 346
Location: Sheffield
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| Posted: Sun Nov 17, 2019 3:49 pm Post subject:
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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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2002 Porsche 996 C2
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Grey996
Spa-Francorchamps
Joined: 24 Jan 2017
Posts: 346
Location: Sheffield
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| Posted: Sun Nov 17, 2019 4:58 pm Post subject:
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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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2002 Porsche 996 C2
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deMort
Dijon
Joined: 21 Mar 2015
Posts: 7593
Location: Brighton
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| Posted: Sun Nov 17, 2019 5:26 pm Post subject:
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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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My Daughter's Crowdfunding has hit the target .
Thank you all so Very much .
She's not going until july 2020 though .
7pm - 9pm
Now At An Indy.
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Grey996
Spa-Francorchamps
Joined: 24 Jan 2017
Posts: 346
Location: Sheffield
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| Posted: Sun Nov 17, 2019 5:40 pm Post subject:
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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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2002 Porsche 996 C2
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deMort
Dijon
Joined: 21 Mar 2015
Posts: 7593
Location: Brighton
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| Posted: Sun Nov 17, 2019 6:38 pm Post subject:
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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 .
Thank you all so Very much .
She's not going until july 2020 though .
7pm - 9pm
Now At An Indy.
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Grey996
Spa-Francorchamps
Joined: 24 Jan 2017
Posts: 346
Location: Sheffield
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| Posted: Sun Nov 17, 2019 6:56 pm Post subject:
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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 
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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2002 Porsche 996 C2
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
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| Posted: Sun Nov 17, 2019 7:17 pm Post subject:
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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 .
Thank you all so Very much .
She's not going until july 2020 though .
7pm - 9pm
Now At An Indy.
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wasz
Sepang
Joined: 28 Dec 2012
Posts: 2998
1999 Porsche 996 Carrera 2
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Grey996
Spa-Francorchamps
Joined: 24 Jan 2017
Posts: 346
Location: Sheffield
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| Posted: Wed Nov 20, 2019 5:33 pm Post subject:
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It’s not a 9mm so I’m stuck! Are there any other socket types that Porsche use?
_________________
2002 Porsche 996 C2
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
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| Posted: Wed Nov 20, 2019 5:51 pm Post subject:
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I'll check on a spare gearbox for you tomorrow if you like.
MC
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kurlykris
Magny-Cours
Joined: 30 Jun 2014
Posts: 2576
Location: Warwickshire
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| Posted: Wed Nov 20, 2019 5:58 pm Post subject:
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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 
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1998 996.1 C2 3.4 with "Aerokit Cup"
2006 Boxster S sport chrono
2010 Mercedes E350 AMG Sport
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