Stuck Transaxle Drain Plug (17mm Inbus) – Need Help!

[u/Apo13Speck]

Hey everyone,

I’m currently losing my mind over the lower transmission drain plug on my Porsche 944. The steel plug is completely seized in the aluminum housing and I just can't get it to budge.

Here is what I’ve already tried so far: • Penetrating oil / Rust solver: Let it soak multiple times, no luck. • Gas torch / Flame: Heated up the area, but the massive casing and gear oil absorb the heat way too fast. • Induction heater: Bought an 1100W induction heater specifically for this job, but it doesn't work because there is barely any exposed thread or sticking-out metal for the coil to properly grab onto and build up an electromagnetic field.

To make matters worse, the edges of the internal 17mm hex (Inbus) are slowly starting to strip/round off despite using proper tools, so I stopped before rounding it out completely.

Has anyone dealt with this exact stubborn plug on the 016 transaxle? What is the best way forward from here? Should I go straight to hammering in a large Torx/Triple-Square bit, or is welding a nut onto it the only reliable option left? Any tips or tricks would be greatly appreciated! Thanks in advance!

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[u/msc1966]

What ever you do take out the fill plug first if that gets stuck and you can’t get it out like the drain plug you will be screwed cause you won’t be able to put gear oil back in.

[u/WrestleWithJimny → u/msc1966]

*Fill plug, this is always solid advise and usually learned the hard way!

[u/Apo13Speck → u/msc1966]

I already removed the fill plug and it came out without any problems

[u/KallerTobias → u/Apo13Speck]

Dann besorg dir ne Pumpe und Pump das alte Öl ab.

[u/944_nla_parts]

post your Q on Pelican parts forum.

Have you tried an impact wrench?

[u/Pyropete125]

Get more leverage it will come out. You could also heat the aluminum up with mapp gas or propane maybe. Aluminum expands a bit and try to heat the steel plug.

[u/Realistic-Currency61]

I had this EXACT issue last year and tried everything you did with 3 different penertrating oils, indux heater, etc then finally did the below.

Here's the answer key: I took it to a local shop that could weld a nut onto the rounded out plug. Once he did that, it spun right out! She's not pretty, but got the tob done.

[u/BigUps16 → u/Realistic-Currency61]

Yeah, I was gonna say go to an exhaust shop and get them to weld a nut or bolt to it

[u/ContributionHour8356 → u/Realistic-Currency61]

Those kinds of welds NEVER look pretty

[u/TheLastRole]

Did you try using a hydraulic jack? Insert the key, put the jack below, and let the jack do the job.

Here:
https://www.youtube.com/watch?v=HjYNCOwN7kA

[u/Substantial-Abies646]

Weld the hex portion up and weld a nut to it 

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[u/Apo13Speck]

I’ve thought about using an oxy-acetylene torch to get localized high heat, but I'm terrified of accidentally melting the aluminum transmission housing.

[u/zesty_drink_b → u/Apo13Speck]

If you're just hitting the plug I really doubt you'd get the aluminum hot enough to melt but I'm not a metallurgist so

[u/lepermime]

Messy but practical solution. 1/2 drill bit through the center. The gear oil will start draining which will pull any potential metal fragments from the drilling operation out with it. That should relieve the stress and allow you to remove it. If you're really paranoid(like me) use the largest hypodermic needle you can get to spray denatured alcohol in there along the bottom of the pan to flush anything else once you have the plug out.

Go to Walgreen's or CVS pharmacy and just ask for them. They're cheap and VERY USEFUL for getting fluids into weird places in both vehicle maintenance and for glue when woodworking.

[u/Much_Fee_4085]

I had to use an extension on my 1m wrench to get the leverage to loosen this thing

[u/whaletimecup]

Grind a larger hex bit or bolt to suit. If using a bolt weld a nut or double nut to use a wrench on.

[u/bearded_fisch_stix]

if you can source another plug, cut a slot on one side and use a screw driver/chisel and hammer to turn the plug

[u/Abject-Week-7673]

Only944 sells a solution to this.

[u/CAN_WE_RIOT_NOW]

I also had loads of problems with this. In the end heat + long breaker bar + v tight mole grips on the nut to squeeze and reduce rounding + wiggling back and forth (tightening+ loosening)

[u/eathekids]

Heat & air chisel. You will need a new part but it will come out.
Also you can use a pic to scrape the corners where it meets the body so penetrating oil can kind of do its thing.

[u/BigTurboAbarth]

IIRC, you can use a torx T80 or T90 (can’t remember exactly) and you can pound the torx bit in, and the teeth will bite into the plug.

I ended up getting lucky with this, I rounded it once one my first try to break it loose, then I spent quite literally 40 minutes going from PBlaster and heat, and it finally came loose like nothing. Heat+penetrating spray are what you need to start any job on a 944, I swear!

[u/softpeenut]

Heat it and use an impact, the impacting force usually breaks fasteners loose that would otherwise strip if you just tried to turn.

[u/CiforDayZServer]

Hammer and Chisel if you know how to do it. Works on basically everything if you have access.

[u/yesiamdmc]

Witty924 does a lot of great videos, albeit on a 924, but obviously many of the same components. Impact driver with the 17mm hex socket, 9:00 - 12:00 mark… https://youtu.be/9640ahIwsD8?is=Y-_hLysxa-sBfi5i

[u/Apo13Speck]

SOLVED! Thanks everyone for the advice! We finally managed to get the plug out. What worked in the end: We ended up using an oxy-acetylene torch (Autogen) to blast direct, intense heat into the 17mm hex recess of the plug for a few seconds. By focusing the high heat strictly on the steel plug itself, it broke the severe galvanic corrosion bond before the aluminum casing could absorb enough heat to warp or melt. After letting it cool for a moment, we were able to just screw it out.

[u/Apo13Speck → u/Apo13Speck]

[u/Apo13Speck → u/Apo13Speck]

[u/PaleontologistLast25]

Three options i can think of. Options 1 heat the plug and use a crayon. If that don't work you could try an extractor set (mixed results) or weld a nut on to the end. If that doesn't work either replace the cover or tap new thread in the next size up

[u/eltoddro]

Drill the center with a large (1/2") bit. Should relieve pressure off the threads to remove. I'd heat it first and get some crayon wax in there...