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Date:         Mon, 16 Apr 2001 10:41:29 -0400
Reply-To:     "Samuel L. Walters" <slwalters@EARTHLINK.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         "Samuel L. Walters" <slwalters@EARTHLINK.NET>
Subject:      Re: Help! Stripped trans oil filler plug!
Comments: To: Shawn Wright <swright@SLS.BC.CA>
Content-Type: text/plain; charset=us-ascii

Just last week I had to deal with a really trashed filler plug in the tranny I had pulled from an 81 Westy partsmobile. Two of the six sides of the 17mm socket appeared to be almost completely gone. It had rust in it and mangled metal from where it looked like someone had maybe used a chisel or screwdriver and hammer to try to get it loose at some point in the past. Since this van has been sitting for about 4 or 5 years, I certainly was not optimistic about getting it out.

Two days before, I had bought a Sears 17mm Allen wrench so that I could drain the fluid before removal. After using screwdriver blades, files, etc., to clean out the rust and move away the bits of damaged metal that were protruding into where the hex socket formerly existed, I had two good sides, two that had about half of their full height wall intact and two that had no more than 3/16" of their wall left. I worked on the socket until I could almost get the Allen key in by hand, but had no visible impediment of any real size.

Then I lightly tapped the Allen wrench with a rubber headed hammer until it sat down in the socket securely. To my great surprise, it then turned and came out by hand, where the previous day I had needed to tap, no hit on the Allen wrench with the same hammer to get the drain plug loose. (The wrench went into the drain plug with a few light taps on the Allen wrench, but the plug wouldn't turn just from my twists. I couldn't get that much leverage under the van due to cramped space.)

After the socket was out, it would go in and out easily and should be useable in the future if some anti-seize or grease is kept on the treads.

So - with some patience and the Sears Allen key, you might be able to get this plug out and reuse it. I guess Shawn's experience and mine reinforce one of the tips that I had seen several times earlier on the list - always make sure you can get your tranny fill plug out before draining the tranny. I didn't follow it consciously, because I was removing the tranny to sell, but it would have been tough to clean up that drain plug socket from under the van. Was much easier with the tranny on its side in an open space.

Good luck.

Sam Walters 84 Vanagon, orig. owner 89 Syncro, new to me 12/00


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