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Manual box level plug; Stuck!
Topic Started: Mon Feb 2, 2015 3:39 pm (695 Views)
2mercspete
Newbie
[ * ]
Been trying to remove the level plug on my 1993 5-speed manual box (no I didn't take the drain plug out first!).
I have a 3/8 drive/14mm hex adapter but so far I've broken my 3/8 drive ratchet and two ring spanners trying to shift it :crying:
Can't get heat on it 'cos of nearby rubber bits - any suggestions?
Cheers,
Pete
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Mick261c
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More than part of things
[ *  *  * ]
Don't put heat near it, get something to fit snug then rather than pulling on the lever try tapping or hitting it with the palm of your hand this should give it the shock it needs to free it off. Good luck, mick.
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jason3249
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what about a inpack gun :)
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2mercspete
Newbie
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Thanks guys; I broke the ratchet by heaving on with both hands, then broke the ring spanners by hitting them with hands then rubber then Thor hammers. As for an impact gun, there's about 1 1/2 inches between the plug and the metalwork...
Next step, cut a hole in the tunnel to get a straight drive onto the plug....Tomorrow...
Cheers,
Pete
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jason3249
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you cant drill holes lol why not just drop the box :)
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Mick261c
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A bit drastic that mate, why not drive to a dealer garage and ask them to slacken it for you, as they have the special long Allen ky tool, don't think they would charg a lot to do it if anything at all
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jason3249
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true true but saves money :)

could of put a new clutch in at the same time so not all bad....
Edited by jason3249, Mon Feb 2, 2015 8:48 pm.
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PhilG
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I had the same issue. I had 2 homemade 14mm allen keys made from a block of steel, but swinging on the 3 foot breaker bar just rounded the tools.
I got a lend of a 14mm socket, (i guess this is what you have) but i had to swing hard (like shock it) on the 3foot breaker bar to uncrack the seal.

Failing this i was going to weld a long steel bar to the face of the plug as i had the gearbox off the car.

You need more leverage!
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alogaparaloga
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crazy mind
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Just get a heat treated drain plug key, an impact socket to fit the key and a breaker bar (1/2" only) 3/8" is not man enough for the job.
It's also better to lower the gearbox from the gearbox mount plate (4 bolts) joust enough so you can fit things easily and get the car as high as possible or see if you can find a pit. you will have to support the gearbox in its lowered position so as when you pull/push the breaker bar you will not stretch the engine mounts.
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eagle3
Therapy Needed
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Manual gearboxes. What a nightmare.. :lol:
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Mick261c
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No problem with manual box plugs if you use the correct tools and have the knowledge
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Chris Martens
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Hazet no. 2760 and and in case of need an additional pipe opens each and every gear box or differential plug:

Posted Image

regards,
Christian

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2mercspete
Newbie
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Well that didn't work - trying to put pics on

Cheers,
Pete
Edited by 2mercspete, Thu Feb 5, 2015 1:41 pm.
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Mick261c
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That's the correct tool we used at the dealers, makes life a lot easier that chris
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2mercspete
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Try again
The bits I broke (3/8" drive)
Posted Image

The bits I made - 5 x 30 x 500mm strip and 1/2" square bar through 1/2" hole filed square and welded ( welder don't like high carbon steel)
Posted Image
Posted Image

Thanks for all the suggestions, all good stuff but I needed to do it lying on my back outside...
Cheers,
Pete
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