Air Impact Tools - The only way to work on stubborn nuts and bolts.

 

I was not aware that the threads in the trans axle were of the straight variety.. They do make plugs for hydraulics that are straight threaded with an O-ring that seat and seal... I use them on hydraulic blocks on moulding machines all the time. (2000 psi) does anyone know what the thread is? This would be cheap and would avert this cross threading situation... If no one knows the thread outright I will pull my fill plug and find out... I always thought the problem was time and heat....IT most likley is BST (british straight thread)..

 

Dwight, I don't know what the actual thread cut is but I bet someone like Rennlister Hans does. You could probably sell many hundred straight threaded solutions to the plug. The OEM is a nightmare for every owner. I mean, what other vehicle has a FAQ list that highlights "Take the top fill plug out first because you probably can't get it out and you want to have gear oil in the car to get it to a machine shop"?

I don't know about an O-Ring seal though. What is it supposed to sit in since the hole is all threaded? You can't just squish it against the face of the hole. Unless bolts are made that house the O-Ring in the head and it makes a seal with the face of the hole. Or maybe just a regular copper crush ring?

 

You canpick up a heavy duty (better quality IMHO) socket like this from any big rig tool place for less than 10 dollars. It is a pretty common size on a big rig and it comes in a 1/2 instead of 3/8th. I always use the 1/2 and a breaker bar.
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Teflon tape.

 

Teflon tape may not be the best idea. Because the threads are mismatched the teflon will get cut and some of the tape could float around in the tranny and clog something.

I sort of like this ring seal of some type idea. Or just make sure you take those plugs out every couple years with a well fitting drive and clean out the plug hole well before you try and stick the drive in.

 

Most old-school VW shops have a 17mm slug/key for this purpose. Stick the slug in, smack the crud out of it with a metal hammer for a while, then use the biggest breaker bar you can fit in there--being careful not to side-load the tool.

Then, once you strip it into a nice round hole you can try the JB Weld, or pounding in an oversized torx or triplesquare key, until you finally weld a key in place or convice yourself the tranny fluid is actually ok as is.

 

Dude,,,have you been hiding in my garage...........?

Thanks, I needed a good laugh today,, and that was it..