calling on NSMA and other mech/auto inclined astute

[dweller]

i hope this is the right group to shout out in, am replacing driveshafts in a Geo Metro, 95. No problems with the driveshaft work.
But...i drained the transaxle fluid using a 3/8" socket wrench to loosen the plug, drained it. Put it back, yanked the driveshafts off, replaced, and now going onto refilling the trans fluid.
sigh...

the plug to fill is the same type as the plug to drain, but set up on the side. And it appears the last joker who checked/filled the fluid either put the plug in with a torque hammer...:shrug: and the plug has been wallowed/buggered out so that a 3/8" socket just slips...the hole the wrench should fit in should be square, it's not ...almost 5 points in there now.
I've already tried a cold chisel and hammer to tap it around, no giving, plus no room to swing the 3#hammer and it's just mucking up the plug more.
I haven't tried heat yet, since i'm under the engine etc. And now it's dark and i'm beat.

Does anyone know of a specific tool for this application that could be purchased to work out this *&^%$!! plug?

I realize that the sucker could be stripped in there, and is going to call for a major dismantling to remove it. But anything that might get me a leg up on conquering this freakin' $4 plug would be mucho appreciated.

i guess i'll get back on it in the morning.
many thanks for any advice.
dp

[Longhorn]

1. My husband suggests

that you try a tool called an "Easy Out." They come in different sizes depending on the size hole that you have or that you can drill into the plug. He says you can get them at any hardware store for a couple of bucks. You will have to get a new plug as it ruins the old one but he says that's how you get broken lugs and bolts of all kinds out.

Good luck!

[dweller]

2. thanks

i've thought of it....ask him how deep i might have to drill for the easy out?

i don't want shavings to end up in the trans. :(

yeah, a new plug is priority regardless of the remedy.

i appreciate it.
dp

[Longhorn]

5. You only have to drill deep enough to get a "bite" on it.

It's hard to say how deep that may be -- could be you have to drill all the way through the plug.

He says he wouldn't worry about the filings because he doesn't think there will be enough to be a problem but you can always run some differential fluid through there to flush them out if you're concerned about it.

We're off to the Rose Bowl tomorrow so will check in Sunday to see how it turns out. Again, good luck!

[dweller]

6. thanks LH and to your hubby too.

that may be my route.

I'll post here again with my results i'm sure.

enjoy the game!
dp

[Wilber_Stool]

3. That's easy

Just turn the car over and use the drain hole to fill it.
Don't like that? Then you'll like this even less.
The only thing I can think of would be to drill out the plug (you'll need a right angle drill) and get a self tapping bolt to screw in to it.
I don't think heat will work. Aluminum is a great conductor of heat. If you try to expand the case, the heat will transfer to the plug and nothing will happen. I don't think an extractor will work either. Aluminum is too soft.
Good luck.

[dweller]

4. at this point, i've considered it (turning it over)

and i've kicked myself for not looking at the fill plug BEFORE i drained it...i could have driven it to warm it up and loosened it, or to a shop to remedy it first.

but at this point, i'm stuck with it here in the drive.

it's coming out one way or another, just was hoping some tool for this was available.

thanks WS.

dp

[Kolesar]

8. I like the idea of heat

Whether the case is Aluminum or cast iron. If the plug & case are two different metals, they will expand & contract at different rates and break the molecular bonds. At the moment, it looks like he will have to drill out the easy-out. Some motor oil on the drill will help.

[dweller]

7. aarrgghhhh......

after purchasing an easy-out from auto motive shop, his recommended size, drilled through the plug, tapped in the easy out, put a wrench on it and applied pressure to back it out...

and snapped off the easy out, in half. Now the broken part is lodged in the hole in the plug.

i'm not a happy camper at this point in this game.

there's more...but i'm too pissed off at the moment to even write it.

maybe later. . .
dp

[dweller]

9. the trans is out

and sitting in the back of my Subaru...that #%$!@ plug is still in the case.

heading to a shop in the morning to see what it will take to get it out.

just thot i'd update.
dp

[NMDemDist2]

10. that just sucks so bad man

really


good luck

[dweller]

11. oh thanks

just another day of the simple becoming confounded.

i'm going to get that sucker one way or another, lol.

dp

[dweller]

12. after consulting 3 different machine shops/mechanics

here in CH,NC with no luck (other than sending me to any other name they could think of to look at the trans)
i traveled over to Ral to a mechanic related to the car owner's husband, who sent me to another specialist who pronounced the magic words:

"I can do it" :)

said he'd take care of it in his off time tonite, i pick it up tomorrow. Hoping for the best.

dp

[NMDemDist2]

13. good heavens dweller!! what a nightmare!

hope you have good news tomorrow :)

[dweller]

14. update

got back the trans, took $40 just to get the old plug out, cleaned up, and a new one that WILL NEVER BE TIGHTENED like that older plug. :grr:

So, the trannie is back in, and now i'm back where i started, or left off...just getting the driveshafts back on and all of the rest of it back together.

Ran out of light and energy, so will hopefully finish up this oh so fun job tomorrow.

SIL coming over tomorrow to help out and learn a bit of 'mechanic-ing' in the process. It's his wife's (my oldest) car anyway, so he has to get his hands greasy some too.


thanks to all for the ideas, good wishes and interest in my minor ordeal. :)
dp

[Longhorn]

15. Wow, what an ordeal!

I'm sorry the Easy Out didn't work. It's always the littlest things that cause the most trouble! These tasks sure do require patience! Lucky SIL to have a chance to learn some of this stuff. I think it's becoming a lost art!

[NMDemDist2]

16. $40 plus how many man hours and gallons of gas??

good grief!

break a leg (or whatever you wish a mechanic you don't want to jinx)

LOL thanks for the update....

[dweller]

17. Wheee. . .

okay, all is back together, and upon warm-up to check for fluid leaks (oil, trans gear oil) discovered a coolant leak off of the back of the water pump.

Talked to a Metro repair guy over in neighboring Hillsboro, older gent who works on them exclusively and he says there is an O-ring on the pipe coming off the back of the water pump, with a set screw to hold pipe in place. Just have to drain the coolant, get the pipe free and replace the O-ring, put it all back and that's it.
The pipe runs over and connects to the lower radiator hose, and on the pipe is a flange that bolts into a cover on the trans. I didn't see that connection on dropping the trans initially, and so in my pulling it free, probably nudged the O-ring/connection out of whack.

oh well, ran out of light and time. SIL coming back in the morning/early afternoon to get his hands in it again. He said he learned alot today. I've convinced him to help out with my next 'fun' project...pulling an engine/trannie out of an old 914. Talk about tight spaces!

so, hopefully all will be done tomorrow, and back on the road Monday. My daughter starts community college and needs her Geo to get there and back.


later,
dp