Hi guys.
I am back. I used to be known as Ernal, but my account stopped working for some reason, so now I am Ernals Ute.

Anyhoo, my problem is this. I got under my ute the other day to check the oil level in my gearbox. I found that the inspection plug has been mangled. Most of the corners have been rounded off. Try as I might, I cant get the damn thing out.

Is it possible to fill the gearbox another way?
Perhaps through the drive shaft hole? I was thinking if I could do it that way, I would remove the tailshaft, drain the box, measure up the right amount of oil, pump it in, and all would be right in the world again.

Is this a good plan? Is there other suggestions?

Welcome back Ernal.

I know the frustrating feeling of mangled bolt heads. This is a pretty drastic idea but it has worked for me in the past. Have you got a wrench with some grippy teeth on it? I have one and it does wonders when trying to remove these worn bolts. Sure it will mangle it even further but you should be able to get it out then get a new plug.

Having to change oil thru the back of the gearbox would be a pain in the ass, so I would try really hard to get this plug out (but Im sure you already have).

Im sure someone else will have an idea.

Thanks Mr Nismo

I have tried really hard. I used one of those Metrinch spanners that grip on the flats instead of the corners, but it still wont budge. I really is stuck in there good.

I think I invented a few new swear words trying to get this out, so if anyone needs some new ones, I'm your man.

sounds like the days of using spanners to get if off are over..

Get a pair of multi grips (they can be locked into place) and they will get if off..

Have you tried spraying with some sort of release spray ie WD40. It might help loosen the bolt.

I think l found that the more you swear the harder it becomes!! Have you tried throwing the spanner across the room, sometimes works for me!

I have sprayed copious amounts of WD40 on it

It wont budge.

I did try the spanner throw. Only succeeded in scaring the dog 8)

Rattle gun.
And heat.

Thats what my friend used to get some heaps stuck in bolt of his 13B engine.
(Well the mechanic did.)

I had the same problem with one of my gearboxes. So I just bought another one for $50....

No room to get anything like a rattle gun on it.
The gearbox is a 5 speed, and there isnt a lot of room between the plug and the floor well. I was hoping to not have to pull it out to fix this problem.
And as it is a 5 speed, I would like to try and hang on to it (especially for the sake of a mangled inspection plug)

Is it possible to fill it from the tailshaft hole?

i cant see why you couldnt fill it from tailshaft hole as you use that to drain it, check gearbox specs to find out how much oil you need, im picking itll be a slow processes like that and youll probably need the gearbox to be out of the car upsidedown to get enough oil in

i was also thinking as these plugs are so chunky you could probably drill a fair size hole through it sideways then shove something in it and turn that

have you tried vice grips they usually get stuff like that after a bit of mucking around, also try tightening the bolt a little more then try undoing it as this sometimes loosens it up a little

I think you can take the shifter out and (slowly) fill it from the top. The problem is knowing how much to put in. Overfilling is a problem, and the specs aren't a lot of help (depends on how much drains out, whether it's the stock transmissions, etc).

These can be *really* tight, but I managed to get mine turned out eventually. When you put a new one back in, don't tighten very much. They don't need a lot.

To get rounded bolts out, use locking pliers (called "Vice-grips" here) and lock it with all your might. This is before you try to start turning it! Use a pipe on the wrench handle if need be. If the pliers unlock, turn them around so you are continuing to lock it as it turns. Sometimes using a hammer to bang the wrench handle can help.

You might also try a plumbers pipe wrench. These bite in as you turn. To get enough leverage w/o putting the car on a hoist, use a pipe to extend the handle.

if your worried about getting all the oil out just stick the hose in the top and let it rinse out with water for 5 minutes

nah maybe not but i found when trying to get the plug out of my diff the shock of hitting the wrench with a hammer was a lot more effective than heaps of force and leverage using long handles/extensions etc.