Hi

I'm new to this site but would like help with the transmission drain plug which has been mangled and the removal Allen key won't stay in the plug to remove it. Anyone able to provide any tips how to get the plug out so I can drain it? Thanks 

Which engine and gearbox does the car have? Can you post a photo of the state of the plug,

It's a 1.9 turbo diesel Mark 1 Fabia, 5 speed gearbox is that what you're asking? The hollow of the hexagon is not holding the tool in order to extract it. 

Any suggestions much appreciated 

 

 

 

 

An old school drain plug wrench has tapered male hexagons and can be hammered and rotated at the same time, the hex socket probably does not have parallel sides so old school may win over on this one, failing that a chisel.

Thanks JR will have a go - let you know how get on 

Try smashing in the next size up Allen, or even a torx bit with a hammer 

Yeah! Make it have it! Show it who is the boss!

22 minutes ago, J.R. said:

Yeah! Make it have it! Show it who is the boss!

 

But don't bust the gearbox casing

Attempting it after a longish drive or after a hair dryer is applied to the general area for several minutes ought to help prior to any chiselling or similar. The alloy of the gearbox should expand quite a lot more than the steel plug.

Ok, smash was perhaps the wrong word. Maybe encourage would have been more apt 🤔🙃

Have you managed to loosen the fill plug OK? Best not to drain the box before making sure you can...

Number one rule - if there's a separate fill/level plug check that it fully comes out before trying to remove the drain plug (unlike in the video). 

 

If you can borrow a hex head that will be better than an Allen key as you can get bigger and longer socket handle or spanner on for more leverage and extend the handle length with over sleeving.

 

Always first clean the plug area before starting, spray and brush.  Personally I never worry about what others say about threads I spray something like GT85 as a cleaning and penetrating/releasing fluid and lubricant.  Normally personally, ignoring what others might say about threads, I try to slightly tighten before loosening - but in your case I wouldn't as it depends on how tight or not, or over-tight the last person went.  Don't overtighten when you put the plugs back in.

 

I'd always fully warm the oil before draining, easiest way is spirited driving, and I leave to drain as long as possible, that way more existing oil and containments are drained leaving less residue in the box and more fresh new oil going in so less diluting the effects of the new fresh new oil.

 

Refill slowly with the car level, I got more out of my wife's 2015 Mk3 than I could get back in so they must have used a different method of (over) filling for that I also had oil coming out when I checked I could remove the fill plug with the car cold.

 

 

Edited 27 February, 20224 yr by nta16

Depending on the amount of thread protruding from the gearbox it might be possible to use either a large set of moles or a pipe wrench to grip the outer. But then only after a trip to VAG to buy new gearbox plug, and tool store to obtain new socket. I believe the gearbox oil plugs are square sided, possibly 7/8 mm. Round here I see this a lot. Nut is 13mm, so local backstreet guy uses a 12mm and a hammer. Common from my son's recollect of job placement schemes in local fast fit places. He tried this once helping me. My boot hit rear end before hammer hit socket.

Jars, the "correct term aka Haynes is "persuade". 😁

6 minutes ago, VWD said:

I believe the gearbox oil plugs are square sided, possibly 7/8 mm.

 

He said it's a hexagon hollow type....

 

On 26/02/2022 at 18:31, RoverP4 said:

The hollow of the hexagon is not holding the tool in order to extract it. 

 

Have gearbox plugs suddenly changed in type. Over my 50+ years of motoring and car mechanicing, sump plugs have always been hex/ external  with gearbox /diff on RWD being square and internal. Unless some "home" bloke has used the wrong type of socket. Similar sort of discussion lots of months ago where ( I believe it was you) said gearbox plugs are either 7/8mm square.

Rover P4 !! And I didn't even notice!

 

Aunty, don't consider using a modern made cast mufti fit plug extractor tool with sloping sides, by coincidence I was only saying today to avoid them.  Generally they're not good fit, horrible shape to grip or get any movement with.  I cut the end tip off the diamond once to get a better fit on a splayed plug, I can't remember if it worked or not but I got the plug out using basic tools, no heat just generous stocks of time and patience which I know can be in very short supply or out of stock for many.  My patience stock soon demises with cars, replaced by the repeated use of four swear words my wife tells me.

 

@VWD I'm glad to hear you corrected your son's mistake, not his fault though I was taught by the lazy and ignorant car trade training.

 

2 hours ago, VWD said:

Have gearbox plugs suddenly changed in type. Over my 50+ years of motoring and car mechanicing, sump plugs have always been hex/ external  with gearbox /diff on RWD being square and internal. Unless some "home" bloke has used the wrong type of socket.

 

No, stacks of both old and modern car gearboxes have the female type.

 

2 hours ago, VWD said:

Similar sort of discussion lots of months ago where ( I believe it was you) said gearbox plugs are either 7/8mm square.

 

Sorry, you are mistaken. In the many years I've spent working on cars I've never once thought that gearbox plugs only come in 7 or 8mm square male.

Edited 27 February, 20224 yr by TMB

13 minutes ago, VWD said:

Have gearbox plugs suddenly changed in type.

Supplies have varied for many years.  IIRC I have 3/8" hex female on the rear axle, formally 3//8" square female,  I forget what's on the gearbox (fill/level only) - tell a lie it's 10mm female hex (IIRC).

 

I assume before you meant to use the grips on the inserted socket tool rather than outer edge of plug.  All the solutions are easier if the person has a lift so lots of room for levers and different muscle groups but lying under a car on just ramps and stands brings lots more limitations.  Especially if the wind is blowing grit and dust up your nose, or your legs and feet are getting wet with the rain or sunburnt - everyday is a better day to be doing something else rather than car farting-about.

 

Edited 27 February, 20224 yr by nta16

Some education for you VWD...

 

https://workshop-manuals.com/skoda/fabia-mk1/power_transmission/gearbox_02r/gearbox_mechanicsoperation_constructiondiff./inspecting_gear_oil/

 

https://workshop-manuals.com/skoda/fabia-mk1/power_transmission/gearbox_02t/gearbox_mechanicsoperation_constructiondiff./inspecting_gear_oil/

My gearbox (FNK) plug is 17mm internal hex. When I changed my gearbox oil I didn't have a 17mm bit so I used the head of a 17mm bolt. I had to suck the oil out with a pump as there is no drain plug on the FNK (and some other Fabia boxes).

 

Edited 27 February, 20224 yr by TMB

"Different versions of oil filler plug and oil drain plug.

I - Oil filler plug or oil drain plug with internal serration 24 Nm

lI - Oil filler plug or oil drain plug with internal serration 32 Nm"   Why is this then, plugs of different materials, they go into different boxes or knowing VW they've changed their mind about their oil specification. 😄   I just went to my neighbour for a 17mm hex as I knew he'd probably have it, choice of two straight off without looking in more than one drawer.   But he didn't know about 5 point hollow Torx and neither did I until neither size of 6 point security would fit.

 

 

Edited 27 February, 20224 yr by nta16

On 26/02/2022 at 18:18, Pete_Ex-Wino said:

Which engine and gearbox does the car have? Can you post a photo of the state of the plug,

 

11 hours ago, nta16 said:

"Different versions of oil filler plug and oil drain plug.

I - Oil filler plug or oil drain plug with internal serration 24 Nm

lI - Oil filler plug or oil drain plug with internal serration 32 Nm"   Why is this then, plugs of different materials, they go into different boxes or knowing VW they've changed their mind about their oil specification. 😄

 

 As Wino states, we either need a photo of the plug or confirmation from below regarding the type of plug fitted as I an quite sure that a hexagon will fit into the star type, but the security feature requires a hollow in the tool to allow full engagement - a hex would have minimal engagement due to the pip in the bottom of the plug.

 Regarding torque values (believe text is wrong and one should be with serrations, one without) this will be based on either the type of drive fitted as the star type will transmit more torque so possibly the hexagon type cannot fully transmit the full torque required but the amount possible is suitable, the actual thread size may differ, or there could be a different seating. VW engineer products so would not change things without good reason.

Edited 28 February, 20224 yr by KeithCheetham
Serrations text wrong

2 hours ago, KeithCheetham said:

VW engineer products so would not change things without good reason.

Reason like, to something cheaper or they've made a mistake, but surely not fiddling figures.  🤣

 

I must admit I didn't see there was a centre security pin on that multipoint drain plug until KC put the enlarged drawing up, I didn't even know they came with security pins, should have guess from VAG though.

 

So if @RoverP4has this then a 12-Point Triple Square (XZN) Tamper-Proof Transmission Drain Plug Bit Socket for VW/Audi/Porsche, possibly 16mm (i only had the quickest of looks), is required, I'm sure every tool kit has one. 🙄

 

1 hour ago, nta16 said:

 

I must admit I didn't see there was a centre security pin on that multipoint drain plug until KC put the enlarged drawing up, I didn't even know they came with security pins, should have guess from VAG though.

 

Yes, the multi point is a 12 point so a 6 cornered allen key may just drop part way in but not engage fully/correctly to transmit sufficient torque.

On 27/02/2022 at 21:06, TMB said:

Some education for you VWD...

 

https://workshop-manuals.com/skoda/fabia-mk1/power_transmission/gearbox_02r/gearbox_mechanicsoperation_constructiondiff./inspecting_gear_oil/

 

https://workshop-manuals.com/skoda/fabia-mk1/power_transmission/gearbox_02t/gearbox_mechanicsoperation_constructiondiff./inspecting_gear_oil/

Thanks, Jim. I'm still in last centuary where sump plugs were hex and gear plugs were squarecor hex.