MichaelH Posted October 23, 2016 Report Share Posted October 23, 2016 Trying to resurrect a gearbox from bits in the garage found a nice case but the oil drain plug is stuck fast into the side. It is difficult to get at because the bulge for the reverse gear is just close The drain plug is nicely rounded off and I can't hold the plug to twist it I have left it with penetrating oil round it but not progressed so far Is it alright to get my oxy-acetylene torch out and heat it or do you try to drill it out Somebody must have resolved this before All useful past experience appreciated Thanks in advance Michael Quote Link to post Share on other sites
Don H. Posted October 23, 2016 Report Share Posted October 23, 2016 (edited) One of these will get out just about anything (as long as you're willing to destroy it in the process. It's how the drain plug on my engine oil pan has been removed at least once. Edited October 23, 2016 by Don H. Quote Link to post Share on other sites
TR5tar Posted October 23, 2016 Report Share Posted October 23, 2016 I've had some success on rounded bolt heads/nuts by using Plusgas and those Irwin reverse spiral flute type bolt grip sockets, although not on a drain plug. Darren Quote Link to post Share on other sites
Motorsport Mickey Posted October 23, 2016 Report Share Posted October 23, 2016 Hi Michael, As Don says the "good ol wrench" will get most of those sorts of plugs out, however I'm not sure you'll get it on because of the space restriction. You could always use the "fluted" extractors which will very likely get it out, you drill a hole through the plug of a suitable size and drive the extractor through it, then slip over a supplied adaptor nut with the fluted profile for it's inside hole and you can get a socket and breaker bar on it if necessary (don't go ape, limit the torque supplied to a commensurate amount). That's a single item buy from Amazon at about £16 or you can get complete sets from them from about £60. If you want a loan I have a set, give me a call or PM me. Mick Richards Quote Link to post Share on other sites
boxofbits Posted October 23, 2016 Report Share Posted October 23, 2016 If you've got a mig welder you could weld a bolt onto it. File a couple of flats on it and use mole grips as tight as you can get them. People often tighten drain bungs far too much. They only need to be nipped up. Kevin Quote Link to post Share on other sites
TR NIALL Posted October 23, 2016 Report Share Posted October 23, 2016 Drill out the Thread from a 17mm Nut and place it over the Drain Plug and give it a few taps with a Hammer now get the Mig Welder and weld both together,the Heat will break the bond and use a 17mm Socket to remove you'll now also be able to reuse it,you may also use a 19mm Nut if necessary. Quote Link to post Share on other sites
Guest ntc Posted October 23, 2016 Report Share Posted October 23, 2016 Drill out the Thread from a 17mm Nut and place it over the Drain Plug and give it a few taps with a Hammer now get the Mig Welder and weld both together,the Heat will break the bond and use a 17mm Socket to remove you'll now also be able to reuse it,you may also use a 19mm Nut if necessary. + 1 works every time. Quote Link to post Share on other sites
MichaelH Posted October 23, 2016 Author Report Share Posted October 23, 2016 (edited) Success! success! thanks all Managed to drill the blighter and then hammered a fluted bar into it (as recommended by Motorsport Mickey): with considerable worry as every blow was metal on metal through aluminium. I then fitted the matching fluted nut onto the bar and with considerable effort managed to start the plug moving Worries : initially my drill didn't bite into the plug. Are they surface hardened? Anyway once in with a small lead drill life got easier and I got thru the plug. A larger drill (to size with the fluted bar) went thru and then the nut: I was very relieved when the plug started to move My experience is that I have to do anything at least three times before I get it right and or I break what is in my hand and I have to start again. It is always a comfort to get onto the keyboard and ask the forumites , I don't have a working mig and I was anxious about welding a nut on with gas as it would put in a lot of heat into the gearbox case As usual Thanks Guys Michael Edited October 23, 2016 by MichaelH Quote Link to post Share on other sites
Motorsport Mickey Posted October 23, 2016 Report Share Posted October 23, 2016 Good result. Mick Richards Quote Link to post Share on other sites
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