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[jbg]

Decided to change gearbox oil today, and even though I know better, made the mistake of taking the drain plug out before the fill plug.

The oil that came out was pretty had it, so I'm glad I'm changing it (recently acquired this 33, a 1988 model with the 1.5 engine).

However, I can't get the fill plug out! Mine is a 17mm hex bolt (I hear some are 12mm allen, which I'd prefer). It's in a very awkward position, but I've tried:

* ring spanner and brute force, both from above and below

* socket with universal joint to clear nearby parts and a pipe over the handle to extend it with more leverage

* heaps of penetrating oil

* gentle taps with a mallet

The bolt is rounding off from all the attempts, so now a 12-point socket or ring spanner just turns on the bolt. A six-point ring spanner bites, but I cannot get it to turn even with the most force I'm able to apply in the small space available.

The only idea I have left is to epoxy a sacrificial socket onto the bolt head to form a permanent bond, use that with a long bar to undo the bolt without any slipping, and then replace the bolt.

Are there any other ways to approach this? If I do the above, what should I replace the bolt with? (Or should I just leave the sacrificial socket on the bolt!)

(My other mistake was starting the job with the 33 blocking my 146ti in our tandem garage. Once I realised I wouldn't be able to start the 33 today, I had to very carefully shunt it out of the garage using the 146ti so that I could go to work!)

[john 33_16v]

Hi,

I doubt it will give you enough leverage from what you've already tried but if you can get a decent bite with your 6 point ring spanner and it's a combination IE the other end is open ended you can hook another ring spanner over the open end mouth to double your leverage

If you can get the bugger out replace with an allen headed one- try alex 33 bits.

Good luck

John
_________________
If it aint broke, fiddle with it until it is!
- - - - - - - - - - - - - -
93 33 16v Mirtle Met
08 Fiat Grande Punto Exotica Red
90 Yamaha FZR600 Genesis- Silky white/red/blue

[paulhide]

If you can get enough bite, use a scissor jack pushing onto the end of the spanner/ratchet to apply as much force as needed from underneath.
(and make sure you are turning the right way!)
_________________
Owner's Club 33 Registrar. Now from P4 & S2 1.7 QV
http://www.alfa-pages.co.uk/viewtopic.php?t=5188

[lee16v]

If either of the above does not bring you joy then you could try applying some heat from a blow torch and give it some shock treatment from a hammer........all depending on your clearance though.

[eagle3]

Maybe a 21/32" imperial socket (a bit smaller than 17 mm - 16 and a half-ish) will just fit on after you filed the rough bits off the bolt..

Use a lump hammer and tap both ways initially - it might just loosen.

It's also good to leave the wd40 a day or so to let it do its work.
_________________
Alfa33 QO 1984
Alfa33 1.3i.e. 1994

[Edward]

Heat… it works really well. Heat it up a few times - nice and hot. Don't set fire to the gearbox oil or the carpets inside the car.

Try and drop the gearbox down by undoing the two bolts at the end of the extension shaft - better access.

Give it a few really good whacks with a decent hammer. (end on - if you can get the swing room) Good for breaking chemical bonds.

Hammer on an imperial socket - as Eagle 3 suggests - it is pretty much all that they are good for. Grind the curve off first (from the socket) - so that you get maximum purchase on what is left of the bolt faces.

If you use a ring spanner perhaps line it with quite a few layers of tin foil. It takes up the gaps and creates a tighter fit. If you use a ring spanner and you can keep it on there - and not slipping, give the head of the ring spanner a few really good taps (and I mean good!) with a hammer (to the outside of the ring) as you apply the increasing torque. Remember - righty tight - lefty lucy!

Get a piece of decent square bar and weld it to the nut - if you can get in there. (the heat from welding will probably do most of the work)

(get a sharp bolster and the right hammer, angle the blade of the bolster just right, dig into the bolt, hitting from below, cut into the bolt head in the opposite direction to the bolt tightening up. It does work - but you have to know what you are doing. Perhaps use a nut splitter to get you started)

Failing that - sit back - put the kettle on - buy my spare gearbox!
_________________
The faster the better.

[lee16v]

Or you could try some heat............

[john 33_16v]

Raising the temperature of the plug considerably might work...


_________________
If it aint broke, fiddle with it until it is!
- - - - - - - - - - - - - -
93 33 16v Mirtle Met
08 Fiat Grande Punto Exotica Red
90 Yamaha FZR600 Genesis- Silky white/red/blue

[Edward]

This could turn into a bit of hot topic…..
_________________
The faster the better.

[jbg]

All sorted!

Found a kind of socket set called a "pass-through socket set" which goes around the socket instead of on the end, which gave me enough room to put the socket straight on the bolt without having to use a universal joint to clear nearby metal.

Crucially, the 17mm socket that came in that set was six-point, so it bit on the mangled bolt head. Couldn't get enough leverage by hand but I was able to use my bottle jack to apply force to the wrench and it came loose!

Will replace with an Allen bolt if I can find one, or a hex bolt but won't do it up to gorilla torque!

Thanks for the suggestions!

[paulhide]

Good stuff.

Yes, see if Alex Poulter has any spares, although I think allen key bolts are worse.

If he doesn't I'll look in my bolt bag and search for Edward's request too.
_________________
Owner's Club 33 Registrar. Now from P4 & S2 1.7 QV
http://www.alfa-pages.co.uk/viewtopic.php?t=5188

[lee16v]

Nice job. Glad you sorted it.

[Edward]

Errr…. did anyone say, allen key bolts are rubbish.
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The faster the better.

[lee16v]

I've looked back Edward........Think you could be the first.......good point made.