Seized & Rounded Gearbox Filler Plug

[belgarboy]

Got a tight fitting hex key and tried to undo the gearbox filler plug on my Freelander TD4. It took a fair effort when it turned until I realised that the plug was still seized and I'd rounded the hex. Any help out of this one would be appreciated!

 

[johnlad]

weld alan key socket to the bolt

 

[jedi]

Or heat it up, take it for a drive, then try it.

 

[teddywood1]

I had the same problem with the transfer box once as it was a metal plug I welded a socket to it and got a long bar and with it being hot from the welding it came off. hope this helps

 

[SES88]

Bolt extractor's, buy a good set, works every time

 

[Irishrover]

Just can't understand why they tighten the gearbox and IRD plugs up so tight
Anyone would think they are holding about 500bar of pressure !!
From memory, it is an 8mm A/F allen key that fits them.
I fitted a copper sealing washer under the heads on mine and tightened them up about the same torque as would be applied to a sump drain plug. I did not use any thread lock or sealant on the threads and have not had any leaks or issues.
I have the sneaky suspicion that they do them up with an impact wrench at build after they have filled them with oil and then fit the complete engine/transmission unit into the car.

 

[hd3]

once asked an LR techie (mechanic) if they'd change the gearbox oil (td4 manual) ..
answer was "we never change the gearbox oil" ..... ( never ? )

~~~~~

that were at a dealership garage ..

 

[jedi]

They dont in most dealerships. .....sealed for life they say?.......sealed for the lifetime of you warranty more llike.......then they dont care as you are footing any repair bills....

 

[jacksta]

I once changed the rear diff oil in a high mileage freelander, the STENCH was unbelievable!
I have never smelled anything so bad, and I would wear ep 90 as aftershave.

 

[belgarboy]

Thanks for all the tips. Sadly working most of the bank holiday weekend so won't have chance to let you know how I got on at least for a couple of days. As for welding, the plug is nylon. I feel like drilling the thing out.

 

[griff2]

when u say weld the allen key to the bolt is the ird/gb not ally?

 

[teddywood1]

the plugs are metal and you have to be care full not to catch the body of the gearbox or ird and I never heard of a plastic plug on a gear box in all of my life. or maybe I am getting to old for this game

 

[Irishrover]

Cant see plastic plugs being tightened to the extent mine were....needed a breaker bar to shift them. They must have been close to 100ft.lbs torque !!
They should definately be steel that's fitted.

 

[niccage]

Irwin tools set? Have used these time after time to remove rounded bolts... I know the feeling, has happened to me when I least expected it then it sets you back a few days sometimes weeks esp. when you planned to finish the work by a certain date or day,
here's me removing one rounded bolt...
Removing a rounded\broken bolt with a special-socket. - YouTube

 

[edwardcraney2012]

The gearbox plugs are ally, and an 8mm Allen key hole, they often are tight I think its the material theyre made from, you could try hammering a slightly bigger torx bit in and seeing if it grips or try tapping the plug round with a chisel, I don't think there'll be much room to do that though.

 

[englishbullterrier]

Introduce yourself here too, would be a help -

Introduce Yourself - Land Rover Zone

 

[Ian jones]

once asked an LR techie (mechanic) if they'd change the gearbox oil (td4 manual) ..
answer was "we never change the gearbox oil" ..... ( never ? )

~~~~~

that were at a dealership garage ..

Theres a lot of service items missed by garages had no prob with my gb plugs , but the ird level/filler plug was a sod