need any advice tranny fill bolt stuck

[sean44kyle55]

went to go change my tranny fluid today since just got the car its a 95 talon tsi awd 5 spd. went to remove the filler plug before the drain plug, thank god, and first tried with a socket and wouldnt move tried a pneumatic ratchet still nothing tried a impact wrench still nothing and i soaked it with pb blaster and still nothing so got the big breaker bar out and it just about rounded the bolt of so just wondering if any of you have had this problem and if so how did you get the damn bolt out any advice is appreciated

 

[Str8Tune]

So the bolt face is now stripped? Or what....

 

[eclipsalon]

where's the filler bolt, on the side? cant you just remove the speed sensor and accomplish the same?
(auto here/havent seen 5sp turbo tranny)

 

[nicholasramos]

Yeah I had this problem, luckily I got it before it stripped. I linked two long wrenches together and gave it a good whack while making sure it didn't slip off the bolt. The quick pressure is what did it for me.

 

[bryanwheat]

where's the filler bolt, on the side? cant you just remove the speed sensor and accomplish the same?
(auto here/havent seen 5sp turbo tranny)

You could, but you can't check the level without removing the plug. The best bet at this poing would be to weld a wrench to the plug and smack it with a hammer. IT should come right loose with the heat and hammer blow. You will need a new plug though.

 

[Str8Tune]

Worst case scenario if you strip it out just buy a bolt extractor kit from Lowes/Home Depot there relatively cheap and work great but on the down side you need a new bolt afterwards

 

[eclipsalon]

i find this kinda funny

On the serious matter, how do you drain them is there a plug? if so... drain it. Maybe someone can tell you how much is suppose to go in any pour it in threw the top( Sp Sen). I cant see the filler being the drain, if so. S.O.L my friend

 

[etay89]

You could, but you can't check the level without removing the plug. The best bet at this point would be to weld a wrench to the plug and smack it with a hammer. IT should come right loose with the heat and hammer blow. You will need a new plug though.

+1 (and I fixed poing to point )

If the nut was rounded off, you can weld a socket to the plug (the next size down or something that fits snug) and then the heat should have loosen things up a bit and use a torque wrench to get it off.

Another alternative is I heard of these sockets that grab stripped bolts and whatnot. You could invest in that.

 

[mattasi]

If it were me I would take a nice sharp file and file the bolt down untill I could fit the next size lower socket on there tight. Like file it down just enough so that you have to softly hammer the socket onto the bolt head. Then connect the breaker bar, get in a good position and give it a strong QUICK pull with everything you got. Watch the knuckles. It WILL come out. Let us know how it goes.

 

[Ambrotos]

@mattasi. That's genius I've stiped so many bolts.. Never even thought about filling the sides down...

 

[luv2rallye]

If it were me I would take a nice sharp file and file the bolt down untill I could fit the next size lower socket on there tight. Like file it down just enough so that you have to softly hammer the socket onto the bolt head. Then connect the breaker bar, get in a good position and give it a strong QUICK pull with everything you got.

+1 on this. I had the same problem with my filler plug. The problem with the factory plug is that it has a slightly tapered head which makes a wrench/socket slip off. If you don't like the previous weld idea, use a 6 point socket - NOT a wrench. Pick the smallest 6 pt socket size (metric or SAE) that you can softly hammer on with no play (head is normally 17mm). After placing your racket or breaker bar on the socket, place a piece of wood over it and use a crowbar against the wood and a frame member (to act as a lever) to FORCEFULLY hold it in position while you (or another) QUICKLY JERK the racket or breaker bar. By FORCEFULLY I mean like with practically all your strength - this will prevent the socket from trying to slip off. It helps to have 2 people.

When you finally get it off, replace it with a normal 16mm x 1.5 x 16mm bolt from a hardware store that doesn't have a tapered head and you'll never have this problem again!
(Replacing that stupid tapered plug should be a mandatory mod - tee hee ).

 

[TSIfreek]

Heat up the case around the bolt this will expand the aluminum case and free up the bolt to come out real easy. Use a propane torch for this. Heat it for about 4 - 5 min that should be long enough. Should come right out.

 

[Robbyd]

if worst comes to worst, drill it out re thread it.

 

[DSML7dropkick]

My brothers 1g awd had a stripped drain plug and we welded a cheap wrench to it.

 

[kthackst]

I would much rather fill via the reverse switch than the speed sensor, but thats just me. I also always crack my fill plug loose first then I do the drain to make sure I am never in a situation like this. Hindsight is always 20/20.

As many of the guys mention above do it the right way. Either welding a wrench, filing down the sides of the bolt, or some easy that grabs the outside of the bolt. Last resort would be drilling, i dont like metal shavings in my trans.

 

[mattasi]

@mattasi. That's genius I've stiped so many bolts.. Never even thought about filling the sides down...

Well thank you, I do what I can I hate stuck bolts..

 

[Str8Tune]

I'm telling you easiest most inexpensive route is buy a bolt extractor kit you can get them from anywhere for less than $15.00 all it is is sockets with grooves in it to cut into the bolt and grab it to pull it out

 

[Chill Kill Kult]

for the love of god, if you weld a wrench to the drain plug, make sure you will be able to turn the wrench 360* aka all the way around.

EDIT: If you have time and a few bucks to blow, maybe find a stripped lug nut socket for a krautwagen (VW, Audi, BMW) they are also 17mm.

the filing down the sides of the nut seems like a solid idea.