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chriss931 · Joined: 28 Aug 2012 Posts: 15 Location: Santa Clara

Problem is exactly what the title says. Its on a 80 931 with the snailshell. One side of the plug (the length of one side of the 17mm Allen) is broken off. Every time i try and loosen it the Allen slips out. Any advise? I'm thinking about tapping on the broken edge with a screwdriver and hammer but don't know if this will cause more broken parts.

fiat22turbo · Joined: 18 Jan 2006 Posts: 4040 Location: Portland, OR

Pull the transmission and take it to a machine shop to pull the plug out for you.
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Stefan
1979 924 Carrera GTS (clone-ish)
1988 944 Turbo S (Silver Rose)

ideola · Joined: 01 Oct 2004 Posts: 15550 Location: Spring Lake MI

Get a 17mm trans filler plug removal tool. Use a hacksaw to cut off the end of the tool. Use a 17mm wrench and see if you can break it loose. I find that using the wrench helps keep the bit flush and prevents it from twisting out of the filler plug. It may also help to spray some PB Blaster and let that sit overnight, then before you start wrenching, heat it up thoroughly with a propane torch. If all of that doesn't work, then the next best thing is to tack weld the cut-off portion of the allen bit to the plug and then twist it out with the wrench. Alternatively, you can use a bolt with a 17mm head and tack weld that in place, and then tack weld a nut onto the threads of the bolt and use that to turn out the filler plug.
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erstwhile owner of just about every 924 variant ever made

chriss931 · Joined: 28 Aug 2012 Posts: 15 Location: Santa Clara

Yeah that sounds like that's what I'll have to do. Do you know what material the plug is by chance m

morghen · Joined: 21 Jan 2005 Posts: 9095 Location: Romania

+1 to what ideola said.

its just some steel...you dont really have to worry about it much...it will weld to most not expensive keys/screws you want to sacrifice.
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https://www.the924.com

chriss931 · Joined: 28 Aug 2012 Posts: 15 Location: Santa Clara

Thanks guys ive been struggling with this for a couple days now and couldn't figure it out for the life of me.

kcoyle · Joined: 15 Jan 2011 Posts: 712 Location: Long Island, NY

Been there. It was ugly.

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1982 931- Stock with MBC at 8psi

Relax, all right? My old man is a television repairman, he's got this ultimate set of tools. I can fix it.

chriss931 · Joined: 28 Aug 2012 Posts: 15 Location: Santa Clara

Ohhhh you aren't kidding. Did you have to heat it up when you took it out or did you just wrench it out

Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

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Toofah King Bad

WeiBe (1987 924S 2.5t) - 931 S3

kcoyle · Joined: 15 Jan 2011 Posts: 712 Location: Long Island, NY

I tried all the basics first. Heat (mapp gas torch), PB blaster, BFH. I actually think it was the heat of the welder that finally helped get it out. Otherwise I believe I would have been screwed. Apparently the PO couldn't get it out either because the fluid in there was gross and kinda low.

I would heat it up ALOT and see how that goes.
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1982 931- Stock with MBC at 8psi

Relax, all right? My old man is a television repairman, he's got this ultimate set of tools. I can fix it.