sailor56

My 1987 carrera fill plug has been stuck in place for some time. I have read all of the posts here about removing the transmission plug on a G50 transmission. Here is what I have tried:
1) Heating the plug
2) Heating the plug and hammering with a chisel counterclockwise (only takes out metal chunks of the plug).
3) Vice grips of all types.
4) Welding a nut on top of the plug (nut broke off)

What I have not tried:
easy out or similar type of device.

It is my opinion that what I have already tried should have put more force on the plug than using some type of insert or extraction device. I have about run out of options at this point. The problem I have is that the transmission is already drained due to the fact that i did not realize that the fill plug hex head was stripped out before draining. All of my manuels never addressed the fact that these plugs are almost always difficult to remove. My thoughts are attempting to fill the transmission from the bottom by pumping in or was wondering if it is possible to fill from the top. It will be difficult to determine if enough oil has been put in. I just want to get the car to a shop to deal with it if possible. Any ideas on this situation would be greatly appreciated as this 30 minute job has turned into a three month fiasco - who would have known.

J. Brinkley

I'd tow it to the shop. There is a breather on top, but I've never seen it.

r911

do a search on Pelican for more ideas to try - an impact chisel is one

unfortunately, you've now learned to never remove the drain plug w/o removing the fill plug first.

Unless you have a lot of $$, I would not tow (flat bed) it in yet... give a few more tries as above before reaching the bitter end.

john d 81SC

Sailor,

Had the same problem when I pulled my engine/trans. HAd been busting my ******* trying everything. Finally took the trans to a very resourceful local Porsche specialist (Paul Schwarz at Cyntex in West Chester, PA). He cut a piece off of the allen wrench I was trying to loosen the plug with, tig welded it into the trans plug, and then attached the welded piece to an impact wrench. Bingo! Took him all of about 10 minutes for the whole procedure.

Hugh R

Don't know about a G50, but If you have enough threads exposed, use a clench wrench, kind of like a plumbers basin wrench, with one fixed jaw and one movable jaw. The harder you pull, the harder it bits in.

scottb

This topic has been discussed in depth on the Pelican board. I'm surprised the nut broke off. You might consider trying that approach again, with a solid weld, and then heat up the case around the plug. Using a long breaker bar, you should be able to crack it loose.

Have you tried tightening it a bit? Some people way that tightening, even a 1/8 turn, and then trying to loosen works.

There's some good information here: http://forums.pelicanparts.com/showt...ssion+AND+plug

Disclaimer: I've not had to try any of the above, so YMMV.

Good luck, and let us know how it goes.

fixnprsh

turn the car upside down and fill it from the drain plug

rbcsaver

Sailor56,
UnlessI missed something, your post does not indicate a anti-corrosion/lube..have you also added one such as PB Blaster and/or Liq.Wrench to the mix I use both. Let it soak a whle, repeat for a day or 2 then reheat and try removing the filler nut+- a welded nut repeated. Also, helps if you ad info such as location. Also, when our help has helped, becaome a member.
regards,
Steve