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Thread: Major help needed

  1. #1
    Join Date
    May 2008
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    Major help needed

    Well i bought my fender few months ago and have taken her off the road to fix a few issues ie. wheel bearings, swivel bearings suspension.
    Whilst doing this work i thought i may as well give it the total once over and do timing belt and all the oils.

    Now to the problem. The gearbox filler has been majorly butchered. Some clown has tried to weld something to the filler and it is unusable for any form of tool.

    Any suggestions on how to fix without pulling the box out ?
    Cheers for any ideas that may help.

  2. #2
    Join Date
    Sep 2008
    Location
    N.Ireland
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    Hi
    You could try gripping whatever is there with a plumbers wrench( you know the adjustable type with teeth), if that won't work you will have to get someone to weld a nut to the mess thats there so you can undo it with a socket. As long as there is something proud of the box to grip or weld to then you should'nt need to pull the box.
    Hope this helps
    Al

  3. #3
    mike 90 RR Guest
    Because it's butchered .... Post up a photo
    Mike

  4. #4
    Join Date
    Jan 1970
    Location
    Somewhat North of Cape York...
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    I assume you have a R380-box. The filler plug is a Torx, cannot remember the actual size. Since it is a tapered thread (and well lubricated, usually ) it should come out without too much fuss after the initial resistance is overcome. My first advice would be to weld on a nut/socket/bolt and unscrew it the old-fashioned way. An alternative could be to take a cold chisel, set on the outer rim of the offending item and start tapping it out. As soon as it sticks out a bit you resort to the polygrip... Good Luck!

    Cheers
    Johannes

    There are people who spend all weekend cleaning the car.
    And there are people who drive Discovery.

  5. #5
    Join Date
    Jan 2008
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    Sydney, West
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    Shano, I am with the rest, do as they have suggested. before the welding try taping with a hammer squarely against the face of the plug, then with a punch or chisel tap from the plug perimeter in an anti clock wise direction. post a photo of the plug.

  6. #6
    Join Date
    May 2008
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    yer ill try get a pic. cant believe what some people do. i had another look an the weld if thats what u call it. It is slaggy.
    I tried hammer and chisel but no luck and nothing to grip onto so guess ill try weld a nut or bolt tomorrow. If that does not work i may try get a grinder in there to get slag off then try weld again.
    Another easy job turned into a hard one thanx to someone elses brainless acts.

  7. #7
    Join Date
    Aug 2006
    Location
    Kingston, Tassie, OZ.
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    Shano, Just be careful, you will need to preheat the area around the plug before welding, obviously a good weld needs heaps of heat, and a sudden expansion of an already stressed casting (Caused by quickly heating a tight tapered thread bolt) could cause it to crack...
    And the Torx bit required is a T-55.
    JC
    The Isuzu 110. Solid and as dependable as a rock, coming soon with auto box😊
    The Range Rover L322 4.4.TTDV8 ....probably won't bother with the remap..😈

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