I went to check the oil in my trans the other day and the plug is STUCK TIGHT! I could heat it with the torch but I hate to heat an aluminum trans case unless it's the last resort.

1) Any other suggestions?

2) Is this a common issue?

As a reminder, this is a Getrag 4 speed from an '83 240D.

Thanks

Dan

It is quite common for these steel plugs to get stuck in aluminium alloy castings. It is a bit of a pain in the arse. You might get some where with penetrating oil especially if the gearbox is out of the car and you can tilt it in such a way that the oil stays put...

...otherwise I'm afraid it comes down to leverage - 1/2 inch socket with 14mm (is it?) hex fitting and a sodding great big grolly bar...

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I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

I forgot the name of the stuff right now, comes in a spray can.

It comes close to freezing the item and shoots a penetrating oil at the same time. You can buy it at Autozone, Advance, O'Reily's, et cet.

I have used it now 3 times and it has really worked 3 times. It comes in a black can, but its name escapes me right now.

I will look on the bench tonight for the product info.

Thanks guys.

Mark - I can swing by the Advance (it's right at the end of the street) and pick up a can - I know of what you speak though I can't pull up the name either. Never tried it and I guess the time is now. Much anti-seize when it goes back in.

BTW - my plug seems to be aluminum. I'll verify that when I get it out.

Dan

The plugs are normally steel. I have an ancient wrench for those plugs left from my 62 fintail. It has a hex on each end with one end in a kink for access. There is no offset so you can put it in and hit it with a big hammer. It always works. Make sure the hex is well seated and you don't allow the hex to slip sideways and ruin your plug.

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

Kroil is a great penetrating oil.

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I have the sale Hazet tool, works great.

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Before you drain it, make sure you can get the fill plug off!

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Both the fill & the drain plugs are aluminum in my '83 getrag transmission.

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Rebe

Rebe - have you had "issues" removing them? How do you handle it?

Dan

They came out ok, but I have the hazet wrench to remove them with. I do use anti-seize on re-installing them.

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Rebe

I am assuming the drain plugs are the same on a 4 or 5 speed. On my 5 speed:

I used a 14mm allen key from memory. There's very little space, so I had to saw off the end a little so it would fit (the shorter of the 2 ends). I then used a breaker bar (steel pipe which fitted over the longer end).

I did have the luxury of a car lift so I could get underneath of it. It was on there pretty good, but it came right out. I was concerned over stripping it out, so I believe it was aluminum. I know when I re-installed, it felt a little "funny" when I tightened it, so I am a little concerned when I drain it again this upcoming spring.

I picked up a can of the "freeze and penetrate" stuff so I'll try it here in a few minutes. I made a removal tool by welding a bolt and a nut together to give some reach so I could use a socket on the hex that sticks out of the plug - pics to come. When I tried it the first time it felt like the tool was digging into the plug and that's why I stopped and posted this thread.

Dan

Just grind a 14mm or whatever it is hex socket down so it can fit in the and then put a 14mm box end on the hex part.

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http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

Let's try this again (entry mysteriously disappeared.....)

Anyhow, the plug is out and the trans was nicely filled. I'll change the fluid some time in the not too distant future now that I can get the plugs out. BTW - my plugs ARE steel. They just felt like aluminum because my first attempt at making a tool wasn't welded well enough and the tool was turning inside itself.

I used the freeze and lube stuff and it DID do the trick. Thanks for the tip on that.

Here's a pic of the tool I made (the one that works) and the plug that it removes. It's just a 14mm headed bolt and an old lug nut welded together.

Again, thanks for the suggestions

Dan

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