The drain plug on my 81 5 speed is reamed out to the point where I can't get a good enough grip on it to get it loose. Darn PO's. Any suggestions...
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Put a nut on it and fill the nut with weld.

 

+1 - Or mig in an allen socket.

 

Wow..I never would have thought of that. By weld do you mead like JB weld? I don't have a welder. The threads on the outside look a little beat too. Only about three or four showing buy I will give it a try tomorrow... Thanks Blown and Zeus. I love this site for this kind of help

 

We both mean weld with a MIG, just find a shop to weld it for you, they should not charge much to do it.

 

Might want to make sure you can get the fill plug out before you continue with the drain plug.

 

Any precautions I should tell the shop about before they hit it with a welder? Are they wleding the nut to the plug or do they need to fill the nut too? Sorry to be such a noob but I don't want to take any chances with my tranny
What kind of "shop" would you recommend for this kind of work?
Thanks again

 

+1000

Get the fill plug out first. Then try turning the drain plug with a cold chisel/Punch and 4lb Hammer - Aim the chisel at about 45degrees to the plane of the rear face of the tranny and at a tangent to the threads . Doesn't matter if you destroy it you'll need a new one now anyway.

 

I got the fill plug loose right away. That one was on good shape but the drain plug was shot before I started

 

You can also pull the cover, clamp it to a work surface and drill the center out of it, then carefully chisel the remains of the old one free from the threads. Lot of work, doable.

You could also do the above, but instead of chiseling, put a nut & bolt through the hole so that the bolt head gets drawn into the recessed allen part. Then, from the backside, tighten the nut against the backside of the plug, it should then turn-out.

 

I just fill the inside of the nut up and the recess of the plug, you will end up with a thumb size blob of weld, when it cools down it will shrink.
That will draw the threads in making it loose.

The shrinking effect works better when filling a nut up from the inside than welding something something on the outside.

Any general auto repair shop worth a damn should have a lot of time doing this kind of stuff.

 

Pulling the cover had crossed my mind but only as a last resort. My concern is could the cover get damaged when the nut gets welded to the plug. It this the kind of operation that I should take to a transmission repair place. The shoops around here aren't going to know anything abouy Porsches.

 

Take it to a general auto repair shop will be better than a trans shop, I doubt they do any welding.

Welding nuts on broke off bolts is pretty much my first plan, simple quick and very little chance of any kind of damage to anything else, unlike using a chisel.

Heck I even used the welder to get one of the races out of my throttle shaft bearings.

 

I am afraid I am going to disagree with what has been posted here so far.

From the picture you have posted there is enough of the allen key hole to be able to get enough grip on to extract.

Do yourself a favor and get a 17mm allen key SOCKET. this way you can put it on a rachet or breakerbar and PUSH towards it while trying to turn. Maybe even have one person slowly turn while you push or visa versa.
As well the socket that you get. Ensure that it has a completely FLAT base, Most allen keys have a slight bevelling on the edge of the tool, you really DO NOT want this. If you cannot find one without this beveling. Then buy one with it and use a hacksaw to cut a tiny bit off the end to give you a true square end.
As well before starting put the socket into the hole and give it a couple really good and hard hits with a hammer! This will help to free it up.

 

Thanks Lizard..I already did the cut flat allen scocket with a breaker bar. I can still get a little bite on the plug but the inside is flared out so as you turn the wrench the allen wrench twists up and out of the plug. That sucker is really in there. You know how you think a job is only going to take an hour or so and you wind up spending six hours on your back smelling PB Blaster fumes It's been that kind of day. Gave up on it when I realized that I would just be making it worse beating on it. A few brews and some Rennlist posts and I'm felling better