The Struggle is Real- Trans Fill Plug
 

OK I had procrastinated replacing my leaking transmission shifter seal. So now I need to check/add some fluid and my repeated attempts to loosen the fill plug has not worked despite applying WD-40 several times between my attempts every few days. Tonight I drove her up on ramps to get enough room to use a breaker bar and wouldn't you know it the plug is sheering on the sides GUYS THIS PLUG AIN'T BUDGING Oddly the plug is a low profile design (unlike the oil drain plug) thus the socket isn't getting enough "bite" to break it loose. I suspect its Tap and Die time but the drive shaft is awkwardly in the way, of course. Any other suggestions??

Good golly . What are you using to open her up. Whatever it is, you should have stopped the minute it started getting round....

Anyhow, Kroil is my go to kreep oil but ATF/Acentone does wonders as well.
Breaker bar or impact wrench..

Heat is also your friend. Heat it up real good with a propane torch. MAP gas also does the trick. Then she should break free.

Yeah I honestly thought I had finally loosened it but realized I had instead sheered the corners. Then I came here.

Heat and the vice grip are needed.

You need to clean out the center of the plug and use a 8mm hex socket or key to remove it.

Here's a write up.

http://www.xoutpost.com/bmw-sav-foru...hange-diy.html

Different Tranny. This one is a GM not a ZF.

Sorry my bad. Hope you not using a 12 point socket. Try a bolt extractor.

Craftsman 952061: Craftsman Bolt-Out 5-Piece Damaged Bolt/Nut Remover Sets

Some of the better 6-point wrenches/sockets are made to "grip" the flats and not the corners. I would try one of those first. Then a special socket for rounded off bolts like these:


http://www.amazon.com/gp/aw/d/B000QW6K8I/

Thanks much guys. This weekend I'll borrow my brother's propane torch (that's what brothers are for, right) and try that. If that still doesn't work the bolt extractor socket certainly looks like a great option.