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jschwerdtfeger Samba Member
Joined: May 30, 2013 Posts: 65 Location: Santa Cruz, CA
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Posted: Fri Aug 09, 2019 10:56 am Post subject: Removing a rounded out transaxle filler plug? (solved) |
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I was going through my list of maintenance items on our "new" Westy when I discovered that the transaxle filler plug had been completely rounded out, looks like maybe the previous owner used the wrong size hex or something. I have a new external 19mm GoWesty plug on order, but does anyone have any ideas on how to remove the old plug? I'm hoping I don't have to pull the whole transaxle... _________________ //JS |
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leecat Samba Member
Joined: September 13, 2012 Posts: 773 Location: Regina
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Posted: Fri Aug 09, 2019 11:05 am Post subject: Re: Removing a rounded out transaxle filler plug? |
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I'd consider welding a bolt into it so that you have an external hex instead of internal. Then keep it for a spare once your new plug arrives. Disconnect the battery and all the usual warnings before welding on the powertrain. Personally I'd disconnect most of the electronics first. Just a normal arc welder does the trick. |
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MarkWard Samba Member
Joined: February 09, 2005 Posts: 17153 Location: Retired South Florida
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Posted: Fri Aug 09, 2019 11:33 am Post subject: Re: Removing a rounded out transaxle filler plug? |
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17 mm hex head bolt I believe. The heat of welding will expand the case and make it easier to remove. Sometimes there’s enough exposed threads a good pair of vice grips will work. _________________ ☮️ |
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dobryan Samba Member
Joined: March 24, 2006 Posts: 16503 Location: Brookeville, MD
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jschwerdtfeger Samba Member
Joined: May 30, 2013 Posts: 65 Location: Santa Cruz, CA
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Posted: Fri Aug 09, 2019 12:13 pm Post subject: Re: Removing a rounded out transaxle filler plug? |
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A 17mm hex just spins, and the plug is flush with the body of the trans, so I think I'm going to just weld a bolt in there—seems like the most foolproof suggestion. _________________ //JS |
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Sodo Samba Member
Joined: July 06, 2007 Posts: 9609 Location: Western WA
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Posted: Fri Aug 09, 2019 12:17 pm Post subject: Re: Removing a rounded out transaxle filler plug? |
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Wire-brush it, the plug should extend a little past the dirt.
And remember that Magnesium burns.
Be careful not to "weld" on the magnesium.
You can buy a 17mm "coupling nut" and weld that into the hole.
Its a long nut, about 1.25 inches long.
Probably M10 size like this:
uxcell M10 X 1.5-Pitch 40mm Length 304 Stainless Steel Metric Hex Coupling Nut, 2-Pack
https://www.amazon.com/dp/B07JPHR8JQ/ref=cm_sw_em_r_mt_dp_U_PxCtDbV36W56D
Or a 3/4" coupling nut is easier to find at your hardware store, grind it down to 17mm, insert, and weld then you have a 19mm hex.
If you are ordering a new filler-plug, get the drain plug version instead,
with a magnet on it,
then you will have two magnets in your trans.
Then you can do the "filler/drain magnet-swap" method (of checking your drain magnet for metal trash). _________________
'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb
Last edited by Sodo on Fri Aug 09, 2019 12:18 pm; edited 1 time in total |
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jschwerdtfeger Samba Member
Joined: May 30, 2013 Posts: 65 Location: Santa Cruz, CA
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Posted: Fri Aug 09, 2019 12:18 pm Post subject: Re: Removing a rounded out transaxle filler plug? |
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Sodo wrote: |
And remember that Magnesium burns.
Be careful not to "weld" on the magnesium.
You can buy a 17mm "coupling nut" and weld that into the hole.
Its a long nut, about 1.25 inches long.
Probably M10 size like this:
uxcell M10 X 1.5-Pitch 40mm Length 304 Stainless Steel Metric Hex Coupling Nut, 2-Pack
https://www.amazon.com/dp/B07JPHR8JQ/ref=cm_sw_em_r_mt_dp_U_PxCtDbV36W56D
Or a 3/4" coupling nut is easier to find at your hardware store, grind it down to 17mm, insert, and weld then you have a 19mm hex.
If you are ordering a new filler-plug, get the drain plug version instead,
with a magnet on it,
then you will have two magnets in your trans.
Then you can do the "filler/drain magnet-swap" method (of checking your drain magnet for metal trash). |
Great ideas, thanks! _________________ //JS |
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Jeffrey Lee Samba Member
Joined: February 04, 2014 Posts: 1488 Location: Wisconsin
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jschwerdtfeger Samba Member
Joined: May 30, 2013 Posts: 65 Location: Santa Cruz, CA
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Posted: Fri Aug 09, 2019 12:33 pm Post subject: Re: Removing a rounded out transaxle filler plug? |
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Yah pawl tools probably couldn't support the Nm require to remove that plug, but pounding a slightly larger SAE might work. I've hit the threads with penetrating oil and a torch with no avail. _________________ //JS |
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PDXWesty Samba Member
Joined: April 11, 2006 Posts: 6246 Location: Portland OR
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Sodo Samba Member
Joined: July 06, 2007 Posts: 9609 Location: Western WA
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Posted: Fri Aug 09, 2019 1:15 pm Post subject: Re: Removing a rounded out transaxle filler plug? |
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That plug is a tapered M24x1.5 in a straight-thread hole. So the taper has already ensured there is no "room to grow". Anything that expands the plug "seems" like it would grab even tighter than the 'rounding out' has already done.
But anything that works.... is good.
Welding is the best bet, and it sounds like it's available..
Another thing you wanna watch out for is don't touch the shift-shaft with the welder, cuz it will arc across internal transmission bearings, and cause pits in the bearings. Just a note to be extra careful waving that welding stuff around under there, and be sure to raise it up high so theres good ergonomics. _________________
'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb |
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32625 Location: Reading Pennsylvania
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DanHoug Samba Member
Joined: December 05, 2016 Posts: 4789 Location: Bemidji, MN
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Posted: Sat Aug 10, 2019 4:54 am Post subject: Re: Removing a rounded out transaxle filler plug? |
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try coating the hex bit in valve grinding paste, available at FLAPS. it can sometimes give enough extra slop filling bite to get the plug out. _________________ -dan
60% of what you find on the internet is wrong, including this post.
'87 Westy & '89 Westy both 2.1 4spd
Past projects can be found at--
www.thefixitworkshop.com |
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MarkWard Samba Member
Joined: February 09, 2005 Posts: 17153 Location: Retired South Florida
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Posted: Sat Aug 10, 2019 10:45 am Post subject: Re: Removing a rounded out transaxle filler plug? |
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Could you post a picture? Sounds like you may not have the actual plug. _________________ ☮️ |
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Alaskaberrys Samba Member
Joined: June 19, 2016 Posts: 1001 Location: SE Alaska
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Posted: Sat Aug 10, 2019 11:17 am Post subject: Re: Removing a rounded out transaxle filler plug? |
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Heat is your friend - what worked for my rounded out filler plug
Heated, soaked w/PBlaster and let sit. Beer. Try. Repeat. (hint: start with a 12 pack ) _________________ '91 Westfalia, Bordeaux Red Pearl 2.1L 2wd Auto
'91 T3 Syncro Doka, Escorial Green 1.9L TD AAZ “Gremian” (to provoke, irritate, exasperate, vex...) |
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Sodo Samba Member
Joined: July 06, 2007 Posts: 9609 Location: Western WA
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Posted: Sat Aug 10, 2019 12:18 pm Post subject: Re: Removing a rounded out transaxle filler plug? |
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Be careful mingling 12-packs, torches and Vanagons.
Ensure your Vanagon isn’t dripping gasoline.
Some do that for awhile.
MarkWard wrote: |
Could you post a picture? Sounds like you may not have the actual plug. |
Good call. Always start with a Pic -they save a lot of time for everyone.
Often there is some of the plug extended outside, that people clamp a vise-grip onto.
There was a recent thread where the guy was flogging a circular cast hole that looked like there might be a totally rounded out hex plug somewhere under that dirt.
It was not the filler plug.
Also, have you unbolted the shifter mechanism? Until you learn how to get around it, its better to just unbolt it. Its makes it so hard to get to the filler plug, theres not much surprise how it got rounded out (among other reasons).
1) VW says the transaxle oil need not be changed, so it likely spent its formative years in oil totally polluted with metal dust, eating itself up from the inside. Sorry. Anyway the plug could be stuck ‘cuz its been 40 years, some of those years ‘cuz the hex is destroyed.
2) inexperienced wrencher, dirt/rust in the hex hole, poor technique
3) luck that your trans got “maintained” at least once , but plug was over tightened. Its tapered thread, thus torque spec is only 14 ft-lbs. so don’t overtighten it, cuz you’re gonna “maintain” this poor trans from now on, right?
Before you unbolt it (because it’s totally “in the way” of accessing the filler plug) take a pic of the mounting bracket because its very simple, yet will confuse you upon reassembly. It gets re-installed wrong so often that there should be a Samba sticky and an official assembly pic. Its becoming more necessary ‘cuz members checkbooks are on fire thus are starting to maintain their expensive (& rare) transaxles.
OK more info than you asked for, and you probably have it out already..... _________________
'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb
Last edited by Sodo on Sun Aug 11, 2019 8:47 am; edited 3 times in total |
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tjet Samba Member
Joined: June 10, 2014 Posts: 3533 Location: CA & NM
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Posted: Sat Aug 10, 2019 1:26 pm Post subject: Re: Removing a rounded out transaxle filler plug? |
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If you try all the recommendations above and are still unsuccessful, you do have one last option before you pull the trans. You can fill the trans through the drain plug with some creativity. You will need to know the correct amount, minus any spillage when you quickly install the drain plug. It will be messy. |
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jschwerdtfeger Samba Member
Joined: May 30, 2013 Posts: 65 Location: Santa Cruz, CA
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Posted: Tue Sep 03, 2019 7:12 pm Post subject: Re: Removing a rounded out transaxle filler plug? |
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Ended up welding a large bolt in and using a breaker bar to get it out, worked like a charm! _________________ //JS |
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