Broke the filler plug on the T20 transmission

[savage 40]

After reading a few posts I decided to check the fluid level in the trans.. I ended up twisting off the head of the filler plug on the top right of the trans...a tiny bit of threads are still showing and my next thought was get it warm then try tapping it loose... But it must be tight! Now what do I do? Dammit!!!

[6X6]

this is the square fill plug? Threaded into cast aluminum I can't see it being that tight If you can catch the edge with a flat punch it may work. PBblaster. Other penetrating oils work but PBblaster is the best, by far. You could cut a slot in the top on either side of the vent to get better bite for a punch, a steeper angle and some good sharp taps should get it moving. Is there enough showing to bite with Vise-Grips? Last resort would be to drill out the vent and use a screw extractor, but that would require a teardown and shaving removal.

[thebuggyman1]

Let's hope you have a steel plug in that aluminum housing. If it is it should be 1/2" pipe and easy to find a replacement plug at the hardware store. Take a hex nut, 3/8, 7/16, 1/2", the biggest that will fit without binding on the case and weld thru the center hole. practice on scrap steel, cause it can be a little tricky. The heat from the weld will expand the metal. When it cools it will probably spin right out. If your plug is aluminum I would try a small sharp screwdriver and try to chisel thru it gently. You don't want debris in your trans. Then try a bigger screwdriver, and so on till it is big enough to turn the plug. Use a cresant wrench on the shaft if needed. Good luck!

[savage 40]

It's an aluminum one with like a small vent hole in it.. There's not enough meat for vice grips just enough to take a screw driver and tap after getting it warm.. and yes it's that tight! Makes me think they put it in a warm transmission and tightened the crap out of it..

[savage 40]

Im thinking the best thing would be take the tranny out, turn it upside down then do the drilling and extracting if I have to.. I would also coat the drill and extracter (or tap) with grease to further catch any shavings... At least that way using gravity and any fluid inthe trans woul prevent shavings from falling in the interior. Shoot just getting to the lower drain plug is a nightmare let alone using a wrench to turn that one! I know it has ATF in it because after running it I saw traces of ATF around the vent ... So I think for now I will drive it and periodically spray it with PBblaster and hope for the best... Dammit!

[PlumCrazy]

Bummer
If you take the T20 out!
Put a 90º fitting on that lower drain plug, a short hose on the 90º to a convenient accessible area (away from chains and prockets) and a drain plug in the other end for easy oil change, NEXT time.
Good luck.

Where are you at?

[savage 40]

Oroville ca , thnks for the tips

[lewis]

Drive the machine while you locate a half case then change it out, keeping down time on the machine to minimum. When you change the case out this would be a good time to check the internals. Working on the case would be much easier and you wouldn't worry about getting contamination on the inside of the tranny. With that plug being so tight as it is. two things may have occurred.

Someone cross threaded it due to its awkward location
The other: its gaulded. This is not a good thing but not unfix-able. If i understood, you said the plug was aluminum. Aluminum and aluminum will Gauld pretty easy with each other and this would mean damaged threads.

Not trying to be doom and gloom but these are a few options or possibilities.

[techfx]

I'm living with this (and a bad seal on the left shaft). So far, I've been filling fluid w/ an adapter from a brake bleeder kit , a funnel and some plastic tubing into the open vent hole.

[countrycummins99]

drill a hole half wat through the plug that way you dont get shavings in the transmission then you an extractor bit the biggest one you can get to work the better lets us know how it turns out

[LarryW]

What if....lol

What if you put a air hose connection on the drain hole or vent. Then apply light pressure, like 15psi or less maybe(dont want to blow a seal). Then if you drill to far, the pressure will release out the hole blowing all shavings out, instead of in? Just an idea. Seems like it would work as long as you don't over pressurize it.

[brushcutter]

Try using a Dremel with a cut-off wheel, one of the small brown ones, to cut a deep slot into the plug, then use an impact driver -the hammer type- to remove the plug. If this equipment is not available, drill a 7/16" hole into but not through the plug. Grind the long point off of a 1/2" flat paddle type wood bit and drive it into the hole. The edges of the bit will bite into the plug, and you can then use a crescent wrench to remove the plug. If done right you will have no worries about chips getting inside the trans.

[savage 40]

that sounds like a plan that may work.. this thing broke off by twisting the square part off the filler plug.. it appeared to be fractured for a long time because the broken pieces were "dark" in color with the the new break being raw aluminum in color.. and only a small portion (20% ?) was fresh aluminum how thick is the plug ? so I don't drill through when I do attempt it.. thanks

[6X6]

.... lets us know how it turns out

Pun intended?

[mike bar]

Good one two-strokes lol:d