Rounded off drain plug

Kando · Mar 30, 2018

Hello TBN,

Trying to change the fluids in my Ford 960 and ended up rounding off the head of the transmission drain plug. Haven't tried channel locks yet but I don't think it'll help. Beyond removing the plug, what could I use to replace it? Would a short bolt work? Looked through messicks and new Holland's parts but the plug itself seems to no longer exist.

Peter 315 · Mar 30, 2018

Try vise grips Maybe napa auto parts or weld a nut on the end and use a new copper gasket

Kando · Mar 30, 2018

Vise grips are my next go to once I let myself breathe a bit. I have no welding experience or equipment so that option is out.

M5farms · Mar 30, 2018

if you have enough media you can grind it square and use a crescent wrench from this point forward .

Kando · Mar 30, 2018

M5farms said:
if you have enough media you can grind it square and use a crescent wrench from this point forward .

Rounded it with a crescent wrench. Not sure of the exact size of the plug head, 15mm wrench was the closest fit, but still a tad bit of wiggle room. Used an adjustable crescent for the extra leverage. I have a vise grip with a straight mouth on it, probably need to pick up a pair with a rounded grip.

fried1765 · Mar 30, 2018

Kando said:
Rounded it with a crescent wrench. Not sure of the exact size of the plug head, 15mm wrench was the closest fit, but still a tad bit of wiggle room. Used an adjustable crescent for the extra leverage. I have a vise grip with a straight mouth on it, probably need to pick up a pair with a rounded grip.

Buy, or borrow, a small Stilson wrench.
You will do much better with a Stilson than vise grips...more leverage.

DwayneB · Mar 30, 2018

And once you get it out Napa should be able to match it up for a new one. If not take some digital calipers and measure the size and thread pitch. You can locate one somewhere. Might even just walk into a new Holland dealer and they might have one.

downslope · Mar 30, 2018

fried1765 said:
Buy, or borrow, a small Stilson wrench.
You will do much better with a Stilson than vise grips...more leverage.

Yes, try to get a pipe wrench on it, something with the longest handle that will fit in the work space available and still grip the plug.

Kando · Mar 30, 2018

Picked up a pipe wrench, and TSC matched the drain plug to a galvanized steel plug in their plumbing aisle. Actually looks almost exactly alike.

Kando · Mar 30, 2018

No go with a pipe wrench, simply can't get a good grip on it.

Peter 315 · Mar 30, 2018

Can you grind 2 flat spots on it and get a better grip

Kando · Mar 30, 2018

I can try, it's a rather tight area, and greasy so need to clean it up first. Have to wait till tomorrow, and find the grinding disc.

DwayneB · Mar 30, 2018

Kando said:
I can try, it's a rather tight area, and greasy so need to clean it up first. Have to wait till tomorrow, and find the grinding disc.

If you can get a solid clamp with some good vise grips and some good smart taps with a hammer might break it loose. Usually a few taps with a hammer does way better than constant force.

downslope · Mar 30, 2018

Kando said:
No go with a pipe wrench, simply can't get a good grip on it.

OK, since you say you found similar in plumbing section I assume it is/was square headed, probably 9/16" or 5/8".
If you can purchase from a tool outlet like Grainger, Fastenal or other, you can buy a 1/2" drive socket either 4-point(best) or 8-point that should be able to get a grip as long as snug fit; better than an end wrench or vice grip.

Individual Sockets

| Fastenal

1'/'2" Sockets - Sockets and Bits - Grainger Industrial Supply

If you do locate an 8-point socket, try to file or grind 4 flat sides.

Also you could try taking a sharp cold chisel and hammering a notch into the exposed thread portion in a counter-clockwise direction. As someone else mentioned the hammering can also help loosen.
Good luck.

shaeff · Mar 30, 2018

Could weld/braze a large nut onto it. Don't put too much heat into it though. Don't run a continuous bead, or if you do, cool it quickly so that heat doesn't transfer too much to the pan.

Let it cool a good bit before removal.

Johnkn · Mar 30, 2018

Or use the correct tool for the job, a bolt extractor which covers the bolt head and bites in when turned counterclockwise. Get a set and have them. This will remove a bolt with a head that is completely rounded. Good luck...

Tractor Seabee · Mar 31, 2018

Post a picture please. We may see a solution to your problem better.

If you are going to use heat; recommend extracting the oil out with a suction pump first. That oil will absorb a lot of heat.

Get a 6 point impact socket a little smaller and try driving it on over the messed up flats. hen use a long breaker bar for leverage.

After the oil is out you can drill the old one out for bolt extractor. Again heat and impact help a lot.

Be careful using a pipe plug as a replacement. They have a tapered thread and most pans do not have many threads in the plug boss. They are made for a straight thread with a gasket. The NAPA guys are pretty good at matching stuff up. None of these type things are unique to the OEM, they are off the shelf somewhere.

Ron

ray66v · Mar 31, 2018

If you have a very large screw driver, (pry bar size), you may be able to cut a slot in the plug, and unscrew it, using wrench on the shaft of the screw driver.

If using various tools fails, I would get a large nut, and weld it to the drain plug.

Johnkn · Mar 31, 2018

or, again, use the correct tool to remove the bolt........

DLTTrekkers · Mar 31, 2018

As it is allready dammaged use a mallot and hit it all all around the outer edge off the plug making it a bit larger and compressing the washer . Then install the correct size 6 sided socket an loosen it .