Removing a rounded out transaxle filler plug? (solved)

[jschwerdtfeger]

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...
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//JS

[leecat]

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.

[MarkWard]

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]

If there is anything of the hex bolt sticking proud you may be able to use a chisel to knock an edge counterclockwise to get it loose.
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Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371

The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794

[jschwerdtfeger]

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.
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//JS

[Sodo]

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).
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'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

[jschwerdtfeger]

[Jeffrey Lee]

https://www.homedepot.com/p/Husky-Internal-Pipe-Wrench-Set-16PL0140/304217608

You might try something like this. I don't know if the plug's hex offers enough depth to engage the tool, but there be enough.

You could also try pounding in a 11/16" SAE hex bit, which is slightly larger than the 17 mm.
http://www.gearwrench.com/gearwrench-84639-1-2-drive-impact-hex-socket-11-16.html

As mentioned, heating the surrounding TX case (and perhaps penetrating oil) may help.
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Camp Westfalia
Camping Tips • Newsletter • Cool Campervan Apparel
www.CampWestfalia.com

[jschwerdtfeger]

[PDXWesty]

https://www.google.com/search?ei=f9JNXZ-1Bavf0gKj1...BoQ4dUDCAo

maybe?

https://shop.snapon.com/product/REX122A
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89 Westy 2.1 Auto

[Sodo]

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.
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'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

[djkeev]

[DanHoug]

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.
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-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

[MarkWard]

Could you post a picture? Sounds like you may not have the actual plug.
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[Alaskaberrys]

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 )
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'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...)

[Sodo]

Be careful mingling 12-packs, torches and Vanagons.
Ensure your Vanagon isn’t dripping gasoline.
Some do that for awhile.

[tjet]

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.

[jschwerdtfeger]

Ended up welding a large bolt in and using a breaker bar to get it out, worked like a charm!
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//JS