I finally got to drill and tap the PTU drain plug on MY 07 TD4 manual.
Previous preparation was taken out on the 5/5/24 by marking the area for the drain plug with a punch, and grinding a nice flat surface for the plug, a Dremel with a fine sander on was used.
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I also used a 5p coin as a guide for the size plug to use, this had an hole drilled into it so the centre could be found.
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The tools i had purchased a while before, which where an M10 x 1.0p taper & plug set.
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A set of different taps and dies.
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The oil used was Smith & Allan 75w-90.
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Two types of drain plug an hexagon & an Allen key type.
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Both types M10 x 1.0
I had to wait on a right angled drill i purchased from Ebay to arrive before i could do the job, once arrived i was able to carry out the task on the 15/5-24
First the car was put on the ramps and the under tray removed, six times 13mm bolts.
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The drain plug area was waiting to be drilled.
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Next quick task was to undo the filler plug, this must always be checked before doing any drilling, you need to be able to open the filler plug.
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For this an aviation long ring spanner was used.
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Next make sure you have your tools for the job close to hand, taps drill etc.
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First tool was the angled drill with a 6mm drill bit.
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This was used slowly so not to burst through and do any damage, be ready with your catch bowl/ bucket when the oil starts to flow.
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Now i really should have followed my own advice above, but the bowl was out of my reach so some oil did flow onto the old bed quilt i had under the car.
So i had to quickly grab my bowl after about 12 minutes the oil had come to just a drip.
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The oil looked quite good condition from 2020 when it was last changed.
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This was placed on my work table next to the new oil waiting to go in, and the measure jug
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The old oil was poured into the measuring jug.
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About 500ml was in the jug add that to about 200ml which ended up on the old quilt came to about the 700ml, the PTU was left to drain for another 50 minutes.
Next the drill bit was changed over to an 8.5 drill which would be the size ready for tapping.
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The hole drilled to size.
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Now i needed to tap the hole with the M10-1.0p tap which there were two of one with chamfer end and one with a square end.
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The chamfered tap was used first slowly back and forth.
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Next the square end is used to make sure the thread starts right away inside the hole.
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This was also turned back and forth a few times, until the tap was fully home on the thread.
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You can still see a little oil coming out.
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My next task was to see if i could get anymore oil out using a syringe.
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No oil came out and the drain hole was ready to accept it's new plug
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I then fitted the 10mm drain plug with copper washer.
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Next i tried the Allen key type plug.
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Both fitted great.
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I decided to go with the hexagon drain plug with copper washer, the PTU was then filled using my pump with 700ml of oil.
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After filling it the car was started up left to run a little bit and the drainplug checked for leaks.
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Oil used is below.
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Around midweek 22nd May i will remove the under tray and check again, another job done now i have to repeat the task on MY14 SD4 Auto.
Below are some of the items you would need to carry out the above drain plug modification.
Drills are from 4mm up to 8.5mm when i do the SD4 i will start with a 4mm jump to 6mm then to the 8.5mm
You could by them single or maybe has a set, i already had a set of drills up to 7mm but bought an 8.5mm from below.
https://www.ebay.co.uk/itm/350874172814
you can buy these single from anywhere.
Oil.
Pump.
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