Hi Guys,

I have a Polo 1.4TDi on a 2003 (9n) that I cant get thre gearbox filler plug off as its rounded off whilst using the 17mm allen key! We've tried to WD40 it as well as welding a bolt into the plug to try and get it off! but nothing works as there isn't enough metal to weld to, even used a chisel! but nothing.

Anyone had this problem and know what else I could try?

Cheers

Edited 22 February, 201214 yr by Mistermena

Can you weld your allen key into it?

Cut the key so its straight, weld it into the plug then get a 17mm socket on it.

Can you weld your allen key into it?

Cut the key so its straight, weld it into the plug then get a 17mm socket on it.

Hiya mate... Thanks for the reply.

I've not tried to do that with the socket yet! But used a 17mm bolt and tried that. The problem is there doesn't seem to be enough surface to weld to in order to stop the welded bolt moving inside the filler plug!... I contacted a VW specialist here in Cardiff and they said that they could get it off for £50 plus VAT!!! But I'm not willing (At this point) to give up and pay out lots of money to remove a bloody bolt!... But I might have to give up and pay the cash out!...

Edited 22 February, 201214 yr by Mistermena

Try using a torque driver but from a socket set, get one slightly bigger than the Allen key and hammer it into the plug, then put your ratchet on and try it, works when I round off allen key bolts.

All the best.

Try using a torque driver but from a socket set, get one slightly bigger than the Allen key and hammer it into the plug, then put your ratchet on and try it, works when I round off allen key bolts.

All the best.

Nice one mate!... I'll give it a whirl! I'm just wondering what and how a garage would use to get the bugger out? Can't be much more than whats been said here I bet?

You need some heat around the casing. It'll give a bit of expansion and ease any corrosion.

Many thanks mate... I'll give that a go an all :-)

Be very weary about heating up local parts of a casting (the gearbox) as this COULD lead to thermal stresses which in turn could crack the gearbox.

Be very weary about heating up local parts of a casting (the gearbox) as this COULD lead to thermal stresses which in turn could crack the gearbox.

Thanks mate... I'm going to try and take off the gear selector and see if I can pout the oil in that way as I can't see any breather hose. Could maybe done through the revesre light switch?

When i had this i put the 17mm socket in there, then clamped molegrips around the outside (there was enough thread for this). The 17mm bit prevented the grips from crushing the plug.

But if you don't have enough plug sticking out to weld, then i can't see that being possible..?

When i had this i put the 17mm socket in there, then clamped molegrips around the outside (there was enough thread for this). The 17mm bit prevented the grips from crushing the plug.

But if you don't have enough plug sticking out to weld, then i can't see that being possible..?

Cheers mate... It'll be worth a go. Does anyone know where the reverse light switch is on this box? I had a chat to my mate and he seems to think that if you take that out you can pour the oil down it into the gearbox!...

That or the speedo drive's not a bad one to use. Make sure the box is drained, then fill it by volume of oil as opposed to level.

When i had this i put the 17mm socket in there, then clamped molegrips around the outside (there was enough thread for this). The 17mm bit prevented the grips from crushing the plug.

But if you don't have enough plug sticking out to weld, then i can't see that being possible..?

Cheers mate... It'll be worth a go. Does anyone know where the reverse light switch is on this box? I had a chat to my mate and he seems to think that if you take that out you can pour the oil down it into the gearbox!...

Pull off reverse light connector (arrow 3).

But you might find it easier to remove the speedo drive #18

The only problem with either of these methods is that you could overfill the box, the only safe way would be to drain the oil (#19 on second pic) and then refill with the correct quantity 2 litres of 75W/90 Synthetic

That or the speedo drive's not a bad one to use. Make sure the box is drained, then fill it by volume of oil as opposed to level.

The gearbox has been drained of oil to remove it when the new LUK clutch kit was fitted. We didn't remove a speedo drive from the box (ie not a cable opperated one) but there was something at the top back of the box that looked like a black plastic T that was connected by a wire! Not sure if this is the speedo and opereated by a magnet pick up, as when we popped it out there was no wire the other end!...

Have you by any chance a picture of either the speedo placement on the box or the reverse light switch please? I dont want to pour 1.9ltr of oil down the wrong on and nake it worse.

Cheers mate...

That or the speedo drive's not a bad one to use. Make sure the box is drained, then fill it by volume of oil as opposed to level.

The gearbox has been drained of oil to remove it when the new LUK clutch kit was fitted. We didn't remove a speedo drive from the box (ie not a cable opperated one) but there was something at the top back of the box that looked like a black plastic T that was connected by a wire! Not sure if this is the speedo and opereated by a magnet pick up, as when we popped it out there was no wire the other end!...

Have you by any chance a picture of either the speedo placement on the box or the reverse light switch please? I dont want to pour 1.9ltr of oil down the wrong on and nake it worse.

Cheers mate...

See my post above ^^^^

When i had this i put the 17mm socket in there, then clamped molegrips around the outside (there was enough thread for this). The 17mm bit prevented the grips from crushing the plug.

But if you don't have enough plug sticking out to weld, then i can't see that being possible..?

Cheers mate... It'll be worth a go. Does anyone know where the reverse light switch is on this box? I had a chat to my mate and he seems to think that if you take that out you can pour the oil down it into the gearbox!...

Pull off reverse light connector (arrow 3).

But you might find it easier to remove the speedo drive #18

The only problem with either of these methods is that you could overfill the box, the only safe way would be to drain the oil (#19 on second pic) and then refill with the correct quantity 2 litres of 75W/90 Synthetic

You're a diamond mate! Many thanks for the pic's of the box!... I've got 75w/90 Motul gear 300 ester oil to go in the box that shouldn't need changing for a very long time. Thats if I can get the bloody stuff in that is!!!

Well guys!

I took the reverse light switch off (22mm, and what a bugger it was to disconnect the switch) and I'm now using a Turkey baster to slowly pour the box oil back in! Going to try and speed up the process by using a syringe! I'll try and post up some picks when the job is doen in a hope that this might help others who may encounter this problem... Many thanks to all that posted on this, you've all been a great help :biggrin:

Well guys!

I took the reverse light switch off (22mm, and what a bugger it was to disconnect the switch) and I'm now using a Turkey baster to slowly pour the box oil back in! Going to try and speed up the process by using a syringe! I'll try and post up some picks when the job is doen in a hope that this might help others who may encounter this problem... Many thanks to all that posted on this, you've all been a great help :biggrin:

If you pull out the speedo sensor you might find it goes in quicker, as it will allow the air inside the box to get out :-)

Well guys!

I took the reverse light switch off (22mm, and what a bugger it was to disconnect the switch) and I'm now using a Turkey baster to slowly pour the box oil back in! Going to try and speed up the process by using a syringe! I'll try and post up some picks when the job is doen in a hope that this might help others who may encounter this problem... Many thanks to all that posted on this, you've all been a great help :biggrin:

If you pull out the speedo sensor you might find it goes in quicker, as it will allow the air inside the box to get out :-)

Job done on getting the 1.9ltr of oil back into the box! The Motul gear 300 oil has to be the best that I've used to date! Silky smooth gear change. There were a few strange noises coming from the engine bay when I 1st started the old girl up that I'll have to look into tomz now as I've had enough of cars for 1 week!... When I get a chance I'll post the pic's

Thanks again for all your help guys :-D

Here are some pic's pf the buggered 17mm gearbox filler plug! And some pic's of pouring the oil in through the reverse light switch...

Edited 23 February, 201214 yr by Mistermena

I had a good look at the car today and there seems to be a strange "Tick" noise that happens now and again! It cant be heard from outside but only in the cabin, sounds like its coming from the passenger side. The battery light now flickers when the engine is 1st started (And then goes out) that didn't happen before. This doesn't happen every time the car starts! Any ideas guys? :sad:

Edited 23 February, 201214 yr by Mistermena

Bump!!!!

Looks like the rattle has gone away!... There was a pen in the passenger door that was making the noise!!! As simple as that in the end...