ZF6 drain plug removal help
Thread Starter
Pro
Joined: Apr 2005
Posts: 590
Likes: 0
From: Boynton Beach, FL
ZF6 drain plug removal help
Went to change the transmission fluid on my ZF6. Used the proper 17mm hex allen head socket on the drain plug. When I tried to remove the plug, the hex deformed the outer edge of the plug. The hex recess in the plug deformed allowing the the hex to turn in the recess. I thought of using heat but there is a paper gasket too close for comfort on the transmission case. Any ideas on how to remove the plug would be appreciated. 
Larry
Larry
Le Mans Master
Joined: Jul 2005
Posts: 5,752
Likes: 4
From: Austin Texas
Using a high heat gun (not Hair-drier), heat up the case at the plug. Use the allen socket again, pushing in very hard as you try to remove. If that fails, I have used a sharp chisel and hammer, impacting the edge in the counter-clockwise direction. Be careful please! 
Race Director
Joined: Dec 1999
Posts: 16,945
Likes: 9
where's the paper gasket? You mean the one for the tailshaft? You won't harm it. The drain plug is a bitch to remove and so is the fill plug sometimes so before you start w/ the drain check if the fill plug comes out, otherwise you will have a real problem, a drained trans and no way to put new fluid back in. The plugs are indeed M17 allens, did you use a cheapo socket?? Soemtimes the cheap stuff has too much tolerance and will round it off. Try using a proper quality L shaped allen wrench and tap it in as deep as it goes, if that won't work get a torx that will just fit and hammer it in.
