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.

Not sure about the room on there.. Id try an extension and impact gun it off... Looks like crappy access in the first place and sometimes its troublesome to be able to put alot of power/torque on the bolt properly when your in a akward position..

If extension wouldnt work add slightly bent U joint adapter and should have enough room under the driveshaft.

Here's another tool that might help in a different way.

http://www.amazon.com/Knipex-8603300.../dp/B000Y03968

Knipex 12" Pliers Wrench. An amazing tool. Maybe my single favorite tool. Once you get past the purchase price, you'll find you use these in many jobs where they excel for different reasons.

In your case, the fact that it can squeeze against opposing faces very tightly may allow it to succeed. At least it will not make things any worse.

have a fire extinguisher handy, (that eliminates the question of "what happens if something catches fire?...........)
Ive also found in some cases the socket profile is flared out a bit at the edge, so I have a few that ive ground flat with a bench grinder. then I take an old beer can, cut out a circle about 1/2 inch bigger diameter than the bolt head, place it on the bolt, lightly tap the socket on, and with any luck the increased grip pressure will allow just one more removal of the plug! :)
good luck! and order a new plug while youre at it!!!!

Different tranny. I can remember when I loosen my fill plug.... It was soo tight. I ended up holding on to the rear suspension some how and kicking the breaker bar! Kind of like I was kick starting a motorcycle lol. One good kick and it broke loose:)

Heat and a real penetrating oil. WD-40 isn't going to cut it. You want Kroil, PBBlaster, weaselpiss (ATF+acetone).

Do yourself a favor and source a new plug, preferably with an internal hex.

I've got a drawer full of Knipex pliers/wrenches. Full Cobra jaws and flat. Wouldn't use it for the bolt in this post.

I find the flats awkard if I had to use them. However, the small 6" handle flats cobras were a lifesaver. Can't remember the exact details but I was plumbing in a new hot water tank, and running black pipe, etc....and I all remember was, as much as I hated my ~knipex flats~, I was glad I had it for that job.

Yes going by BMW tomorrow

The dealer had to special order the plug and won't arrive here until Tuesday so I'll be giving it a try then.

Always frustrating.

Don't know this part exactly, but it always seems to happen to me on "one time use" bolts, making me think the dealer isn't really replacing them every time...

Just keeping you guys posted: I went by BMW to pick up the plug and again was given the wrong plug; an oil drain plug the first time. The parts manager re ordered it this time.

I'm hoping you have it out by now but here is what I would do. It looks like from the camera angle you can do this. Spray it with penetrating oil. Get hacksaw or sawsall blade and cut a nice slot in it only as deep as the hex on the plug. Don't cut into tranny housing, just do a gentle cut. Before cutting get a punch and a hammer and put it in the center of the plug and rap on it a few times just to get a "shock wave" through the plug and this can loosen any bond the threads are having with the case. Gently file all sides of the hex head smooth being very careful that the filing is square to the case and the other sides of the hex head. Get your best flat screwdriver, nice and square( clean it up on your bench grinder if you have to) and put it in the slot you created. Give it a slight tap so that it is seated while still holding it with you hand. Now grab the knipex or channel lock pliers with the other hand and turn both the screw and pliers at the same time. Good luck!