[steffan_miller]

I have a 86 Nissan P/U 4x4 5 speed trans. Somehow on a previous gear oil change, the plug got jammed in place (went in fine but won't come out) on the trans. I have tried a large breaker bar, impact gun, and hammer and chisel on it. All I have managed to do is partially round out the square hole in the plug. I have talked to a few mechanics who don't want to mess with it because they are afraid they will crack the housing (cast iron I think).

My idea was to drill it out and replace with something like a Heli-coil, if they come that large. One Nissan mechanic said he heats them and they come out easy. I find this a little difficult (and dangerous) with the trans in the car and oil in the trans.

Any ideas or suggestions would be greatly appreciated? I would prefer to do it the easy way - not removing the trans if possible.

[4 Jaw Chuck]

Using an oxy/acetlylene torch heat the center of the plug cherry red, let cool and it should back right out. I've never cracked a case doing this and I have done dozens.

[steffan_miller]

That's the procedure the Nissan mechanic recommended also. But, don't I have to worry about setting the car on fire (or at least the trans) since it is full of gear oil?

[60convert]

first make sure the outside is clean then go at it. your not torching on the inside.
Jesse

[steffan_miller]

Thank you both gentlemen. If the threads turn out to be damaged on the case itself when the plug does come out, what would be the best way to repair it? Is there anything like Heli-coils that come in that size and a pipe thread or is there a better way.
Thanks for all your help.

[poncho62]

If the threads are damaged, run a pipe thread tap through it...........