Ird filler level bolt rounded cant undo

help ...my IRD level filler bolt rounded cant get it out ive tried these impact driver / big bar 19mm socket / a welded a nut to the ird bolt but wont weld to ird bolt soft metal .
but can i fill through the ird breather pipe has anyone done this ?

you need to get that bolt undone as it is also the level plug ,unless you have emptied it and put back in the exact amount which is 1.1 ltrs of 75 90's .I definitely welded a bar to mine so maybe it is the nut you are trying to weld on it .

everton said:

help ...my IRD level filler bolt rounded cant get it out ive tried these impact driver / big bar 19mm socket / a welded a nut to the ird bolt but wont weld to ird bolt soft metal .
but can i fill through the ird breather pipe has anyone done this ?

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usually if you hit them enough it will loosen ,keep hammering a socket on before it mushrooms too far then try hitting again if still stuck

Hi , had the same problem , I used a full 6 sided socket , and got a mate to keep the extenton bar level while I used all my strength to move the rachet , had to replace the plug and copper washer , around £3 from L R !

I used a hammer and chisel to turn mine. If using a socket as said above, push it on hard all the time whilst trying to turn it. Long ratchet will help. Use something on the body work underneath as a lever with a block of wood.

IRD filler plug TRL100060
IRD filler washer TFY101060
IRD drain plug TAS100000
IRD drain washer TFY101070

And don't ferget to undo the filler plug before the drain plug.

Hippo said:

I used a hammer and chisel to turn mine. If using a socket as said above, push it on hard all the time whilst trying to turn it. Long ratchet will help. Use something on the body work underneath as a lever with a block of wood.

IRD filler plug TRL100060
IRD filler washer TFY101060
IRD drain plug TAS100000
IRD drain washer TFY101070

And don't ferget to undo the filler plug before the drain plug.

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try my method first next time .its something i come across often

jamesmartin said:

try my method first next time .its something i come across often

Click to expand...

I keep a spare filler plug just in case. Don't think I'll ever forget the fun I had so I always remember filler first.


P7051065 Nr91wQ9

I've had to resort to using an air chisel on more than one occasion.

as Hippo's picture shows there is still enough good flats close to the bottom. If you have a single hex socket, make sure there is no lead-in on the business end of the socket, I have been known to grind a socket down to achieve it, then you can get the socket hex right down onto the remaining good bit. Then use a hammer type impact driver as it does everything to help push the socket on at the same moment as it applies the turning force.

still cant remove bolt .
BUT can i fill through the breather .uploaded pic
as anyone done it this way will it be ok .

It should be OK if you put in the correct amount, but you have no way of telling. If you put in too much the worst that will happen is it will come back out of the breather or it might leak a bit if the seals are worn. If you put in 1 L it will be enough as the 1.1L would fill a dry IRD

Can't for the life of me understand why these plugs are ridiculously tightened up so much.
They are only filler/level plugs and it's not as though they are under mega hydraulic pressure.
Luckily I managed to remove mine a few months ago without damage but it was exceedingly tight
When I refitted it, I used a copper washer under the head and tightened it up about the same as a sump plug.
No leaks, it hasn't been blown out or vibrated loose and fell out !!

They should have a copper washer fitted as standard but peeps sometimes don't bother. The nut sits flat when secure, so removing it is a bit of a shock when it snaps loose, as opposed to a normal bolt that eases loose.

GREAT,,,,,.can confirm i filled ird through the breather pipe from the top of the engine next to turbo filter.i put 1 LTR through the 6mm breather pipe took about hour to go all into the ird but job done . also thanks to bell engineering for confirming it is possible to fill through the breather.

Good result, you can now work out how to remove the level plug anyway, before you forget about it til the next time.
Just hitting it straight on can help by squashing the copper gasket a little, it will also push a little of the metal back into place. Heat will also help as the alloy will expand more than the steel plug. You could also try welding on a nut again, wire brush it first.

Hi all,

have the same problem and am working through the threads.

Speaking of threads doesn't all this extreme force risk damaging the threads in the casing?

Mine plug starts coming out then goes solid so will trying knocking the nut 1st, bit concerned about heat application as there is oil in there.

cheers

terrier

It has probably picked up the alloy thread, guess you will need to make a new thread when you get it out