Diesel gearbox fill plug
 

Hi all.

While doing the annual engine oil change I thought I'd change the gearbox oil while under there.

Yes, I know it's not actually listed for a change, but I'm not a fan of "sealed for life" components that have oil in them. Just can't get my head round how something like a gearbox doesn't ever need an oil change. Maybe the Moon Club folks know differently :shrug:

Anyway, as it turned out, fortunately, I'd heard some general advice about always remove the filler plug first. This is because if you remove the drain plug first then can't get the filler one undone you're in a bit of a spot as you have no oil in the gearbox so no longer have a drivable car :mad: ;).

And guess what....... Somewhere along it's life the filler plug has been mullered. T50 torx just spins. T55 torx won't go in. M8 allen just spins and M9 won't go in.

My thought is hammer and long punch to drive the plug round, which I'm sure will be a pig of a job. I can't imagine that there's space to get in with Mole grips or anything like that or that the plug has enough head depth to get hold of it anyway. If it was a bolt head I could use my Irwin extractors. Is there something similar that will do the trick?

Anyone got any other suggestions about how I can get the plug out :shrug: :bowdown:.

And does anyone have a spare fill plug? I'm guessing I'm likely to be heading in Mickyboy or Trikey's direction for one off something heading for scrap.

Thanks in advance.

Are the filler plugs anything like the seat runner bolts, vary in what "torx" bit is required?

macafee2

They are both Allen key plugs, Freelander1 gearbox lugs are the same.

https://i.imgur.com/gfl0qAPl.jpg1

https://i.imgur.com/knrF3eYl.jpg2

Sump plug fitting is best to use.

https://i.imgur.com/UuTn5Zal.jpg3

https://i.imgur.com/7CHaZvql.jpg4

If that fails then try an irwins.
https://i.imgur.com/VPX55Jhl.jpg5

Success
 

An Update.

Finally got the plugs out :jig:.

All drained down and refilled.

Remembered that the car needs to be level so did a bit of a faff with a couple of jacks and a spirit level.

I reckon that the oil in there had been there for 19 years and while it wasn't horrendous it wasn't great. I'm sure that I put more in than came out :shrug:.

https://live.staticflickr.com/65535/...684d25_w_d.jpg

The changes now feel better and the car seems quieter - or maybe that's just my duff hearing :icon_lol:.

Thanks for the help guys.

Thanks Andy. Can you share with us how you ultimately got the plugs out, please?

Thanks,
Glenn

Hi Glenn.

A set of these did the trick - with thanks to Arctic for the idea:

https://www.ebay.co.uk/sch/i.html?_f...t+Set&_sacat=0

Irwin do something similar on your side of the pond.

And I'm sure that the 30" breaker bar frightened the plug into submission :eek::D.

All lovely now.

Hi Andy,

Ahh yes, screw/stud extractor. Here we also call them Easy Outs. I have some longer ones, but those short stubbies look like they are the answer.

Thanks,
Glenn