Stripped transmission drain plug - Ford 4100

[Other Bob]

I bought an 80's Ford 4100 diesel a couple of years ago and I need to change the transmission fluid. However the plug is stripped, so I can't get it out. It's the type with an inverted 1/2 inch square which was almost completely rounded. I couldn't get any bite with my 1/2 breaker bar so I ordered some extractors. The plug seems to be soft metal as the extractors seem to get a little bit of a bite and then just start eating away material.

I'm not sure what else to try, I was going to try and collapse in the sides so that the threads would be loose but it sits almost flush with the transmission housing so I can't really get much forse from the outside.

Any suggestions?

 

[Diggin It]

Oh No!!!! Here we go again, another 1,000 posts .....


Sorry Bud, inside joke about a stuck drain plug thread .....

As I recall, he had to drill the plug mostly out before he could extract the remains.


Here it is .... start towards the end and read backwards...... https://www.tractorbynet.com/forums/parts-repairs/393632-rounded-off-drain-plug.html

 

[dragoneggs]

Oh No!!!! Here we go again, another 1,000 posts .....


Sorry Bud, inside joke about a stuck drain plug thread .....

As I recall, he had to drill the plug mostly out before he could extract the remains.


Here it is .... start towards the end and read backwards...... https://www.tractorbynet.com/forums/parts-repairs/393632-rounded-off-drain-plug.html

Specifically, posts #1903, #1910, #1912, and #1923

 

[TractorGuy]

NOOOO!

LOL

Maybe try one of these.

Advance Auto Parts - Down for Maintenance

 

[Other Bob]

Thanks for that link... I think. I had to go back a good number of pages to even find anything related to actually getting the plug out. I had no idea drain plugs could cause so much conversation. Sounds like his was more of a standard plug with a hex head. Mine is more like the picture:


That being said I think I'll have to end up doing something similar and drill it out. I don't have a bit nearly as big as the plug, I'm guessing it's close to an inch in diameter. I was thinking about using a small bit and drilling holes in a v - pattern to make a pie shaped section that I can knock out and then try collapsing the rest. My fear is damaging threads or cracking the housing.

 

[Diggin It]

Mine is more like the picture:

You mean yours is SUPPOSED to look like that, right?

My fear is damaging threads or cracking the housing.

Yeah, that was a concern over there too.

 

[Jstpssng]

All that he said was "Drain plug" and everybody started having flashbacks. Good luck, I hope that it doesn't take a year and 2000 posts to get it out.

 

[dragoneggs]

All that he said was "Drain plug" and everybody started having flashbacks. Good luck, I hope that it doesn't take a year and 2000 posts to get it out.

Oh... we are much smarter now after that learning experience and as such, better able to help!

 

[Other Bob]

You mean yours is SUPPOSED to look like that, right?



Yeah, that was a concern over there too.

Yes, mine is supposed to look similar to that but the square hole is almost round.

 

[Diggin It]

Oh, so you need a round peg for the square hole.



Hey, Peanut Gallery .... is this a candidate for welding? Piece of steel rod somehow, in the hole, then welded to the surrounding surface of the plug? Maybe bent like a lug wrench?