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YOUR RESEARCHGearbox filler plug rounded, any ideas?
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Replace oil last week, got some heat into the casing
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My gearbox drain plug rounded on the 944 when I changed the oil last week, got some heat into the casing before hammering a large Torx into it and it undid easily then.
Leading evidence: 'Replace oil last week, got some heat into the casing' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Replace oil last week, got some heat into the casing' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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Suggestion
You can also just cut a slot just using the bade then get a screwdriver (use like a chisel) in the slot and tap it round with a hammer.
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Replace oil last week, got some heat into the casing
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that performed work without a confirmed outcome
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Performed · outcome unconfirmed
My gearbox drain plug rounded on the 944 when I changed the oil last week, got some heat into the casing before hammering a large Torx into it and it undid easily then.
Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.
15 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
911uk: 1 discussions
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Generation: 20261027T022239Z · outcome-qualification-6. Deterministic extraction; no AI model inference. How we use sources
Luckily I tried to remove the filler plug before draining the box only to find the hex bolt is rounded off!
Access is very tight so I can't get a grip on the plug or any space to try and hit a larger key in there.
Other than dropping the gearbox does anyone have any other ideas?
Saw a slot in it with 2 hacksaw blades in your hacksaw (so double width). Then get a steel plate the width of the saw cut, line it up in the slot lengthways and turn.
Hammer a smaller A/F socket onto it.
Hacksaw 1/3 off the side of the bolt and get an adjustable on it - need to cut in the right place to ensure you get enough movement to undo.
Buy an Irwin grip nut set?
My gearbox drain plug rounded on the 944 when I changed the oil last week, got some heat into the casing before hammering a large Torx into it and it undid easily then.
Thanks all, Alex's slot for the chisel worked a treat.
Issue I've got now is that there's something blocking the whole on the inside. It looks like another sort of internal cap where the rod on the end of the filler plug must slot in but I can't get any oil in with this there. I can move it slightly but I don't want it to drop into the box.
Also none of the replacement plugs I've seen are like this so I'm not sure what's going on?
New Top Gear Cats have gone on well and look great though.
Thanks
Slightly embarrassing but all sorted now. Nothing like turning a 20 minute easy job into a hour long nightmare!
Out of interest, what is the other plug for?
That's not the filler plug as you have found out .. i believe that's a selector shaft retaining bolt .. make sure with it refitted you can get all gears please before starting it up .
Thanks, yes luckily all the gears seem to be ok!
The head on the plug wasn't actually a hex after all but looked to be an 8 or so fitting. I wasn't able to get it totally tight so could do with buying the proper tool if you know which what it is and what size?
Thanks
I would have thought it was an 8mm allen key or hex bolt as most of them are on porsche boxes .. i can't quite see from the angle of the bolt though.
Best guess is it's no.19 on the above image from pet.
If it helps then even us mechanics don't always know the right bung to remove and have to look up instructions .
Thanks deMort, I do normally have to look things up but didn't bother with such an easy job! it does look exactly like a filler plug though, if only I'd watched the YouTube video beforehand :bonk:
It's too big for an 8mm and too small for a 10mm so that leaves a 9mm. An unusual size but I suppose it could be?
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