aaron3

Ok, so the plug in the front tow socket is firmly stuck (90GT model). Two questions:

1. What is the easiest way to 'unstuck' the plug (WD 40 with and easy outs?)?
2. Since it will probably be days or weeks before I get to addressing the plug, what is the safest way to attach tow straps to the front, safely w/o ruining something (hopefully won't need any towing service but ...)?

Thanks in advance.

largecar379

since no one has answered........

I am curious about the "plug" you are referring to. Is is actually in the threaded socket (welded to the front frame rail) that the tow hook threads into? I have never seen the threaded socket "plugged", but that doesn't mean anything particularly, just my experience. Every time I have seen a tow hook used, you just pop the bumper cover plug out and thread in the tow hook..... What is the plug made of? Is it threaded in, or is just something someone shoved in to use to keep trash out?

As for a place to hook tow straps.....man, I'd be careful about hooking to (under) the front of a later 928. OB's have tow eyelets for towing (watch out for the spoiler though...)

If you should need to tow it (because of breakdown), I would suggest a flatbed wrecker and winch it on, hooking to something substantial......

--Russ

jon928se

For Russ' benefit the plug is Aluminium.
It threads into the steel tube that is welded into the frame rail.
The "allen" key in the toolkit is supposed to be able to undo the plug - HAHAHAHA ROFL.
The thread is a Knuckle thread (best match I have found) as per attached link
http://www.gewinde-normen.de/en/knuc...d-din-405.html
IIRC the thread is RD22x1/8"

The only way I have found to remove the plug involves a drill - up to about 18mm dia should be OK then a dremel with a carbide burr alternating with small picks to grind/pick out the little bits of alu from between the steel threads of the tube welded into the body. A suitable plug to close the whole up afterwards is one of the rubber bungs that you find at bicycle stores normally used to plug the ends of racing bike handlebars. I just sprayed the inside of the tube with chain wax.

Landseer

That benefits me, too. Thank you, Jon.

jon928se

No dramas, I think I am an Engineering Geek/Nerd. I found the link with all the different threads on it about a year ago after a similar question on the Lansharks email list (Australian 928s) Looked at it again today and found myself looking through all the unusual types of threads. **** for engineers LOL.

FUSE69

Yeah, mine is reeeaally stuck... PO has even snapped off the "allen" key in the plug!!

Not looking forward to fixing that... but some helpful tips here, thanks Jon!

Vlocity

In the interim if you have to be towed.....I would use the tow eye in the rear bumper and have the vehicle pulled on backwards.

Ken

dprantl

I got the same problem on my GT. I was going to try and jbweld a socketed allen all the way into the plug and see if I can get it out that way...

Dan
'91 928GT S/C

Alan

The GTS plugs are rubber - with a puller loop on the front - use that as a replacement I believe they are still available (Porsche learned...).

In the meantime I agree - pull it up backwards - there is no safe place at the front

Alan

Mrmerlin

This is for 87 and newer cars ,before you try to remove the plug , try this get an 1/8 in drill bit and carefully drill just next to the allen key hole
Drill till it feels like the drill went through .then stop. What your doing is making a pathway to the interior of the threaded hole. the plug has a step on it and after you drill through the head of the plug you can now fill this area with some PB blaster. also take the same drill and carefully drill a hole into the center of the allen keyhole you can now spray some PB blaster into the rear side of the plug let this sit for a few days you can also tap the plug with a hammer and a drift or better is a long 3/8 extension this will start to loosen the corrosion thats holding it. spray the PB a few times for a few days.
Put in your Best(strongest ) allen socket. and try to remove the plug. If it spins out then your home free. If not then i would suggest that you use an air hammer with a slightly dull cutting tip to try to twist the head out. If this fails then drilling out the plug is the next last resort. I have gotten 3 out using this method. I have only been foiled by one still stuck
After you remove the plug add some thick grease to the threads if your plug is in good condition then you can wire brush the threads and add some grease to it and reinstall it dont make is very tight though, or get the rubber GTS plug

The OB cars have this tow hook adapter on the outside of the frame rails, Hence the plastic bumper plug and the 87 and newer cars have the tow hook on the inside of the passenger frame rail and the aluminim plug

largecar379

thanks Jon----

wasn't familiar with this, and those 928's I have been in contact with didn't have a plug in the threads!!!

Much appreciated.

--Russ

Richard S

Arrrrrrrrrrghhhhh....the stupid CO did that to mine too.

(CO=current owner )

Rich

ParkerC

Hmm sounds familiar...

After that happened to me a threw what was left of the tool out into my front yard, and never found it. Then I had to find a new one to make my toolkit complete again

TheoJ

Hi,
I've done a few of these now. It is a PITA every time. Forget about unscrewing it if it has been stuck for some years. The bolt is so badly corroded that it breaks after 4mm, leaving the remainder inside the hole. I've seen this happen every time. I even tried hammering the plug-bolt from the side with a chisel. No movement at all.

Best is to drill it out, use the hex-key slot to center, and try not to damage the threads. From there onwards use a dremel tool and a small grinder to carefully remove the remaining aluminum, and just like Jon said: a steel toothpick to peel the threads of the bolt out. It works ok. Takes an hour or so if you're quick.

If you do this cafrefully you will not need a thread cutter in this exotic size to clean out the threads.

regards,
Theo