Engine/Transmission (1998.5 - 2002) Mag HyTek drain plug stuck

[DLBurns]

Went to change my trans fluid today and broke off the 3/16" allen head in the drain plug Luckily there was enough of a stump left for me to grab it with vise grips and pull it out of the plug.

Anyhow... . this plug must have been installed by the Incredible Hulk as I cannot get it to move

Any suggestions on how to get this f&^%& thing off?

 

[Bob Wagner]

I would put some heat on it and use a socket wrench style allen socket.



Did you get your Tstat?





and its 1/4"

 

[plongson]

That dipstick plug gets REAL tight with very little effort. I found that when tighting it up you just barely snug it down and later it is just about right. If you tighten it down "Fairly tight" and check it a day later it breaks loose with a resounding "SNAP". Haven't got a clue why. I'll bet if you tighten to 10 ft/lbs it would take 20 to remove it.

 

[Bob Wagner]

Buff is doing a transmission service

 

[DLBurns]

Originally posted by Bob Wagner

I would put some heat on it and use a socket wrench style allen socket.



Did you get your Tstat?





and its 1/4"

Bob... . the allen wrench I snapped WAS a socket wrench style!

I'm gonna try the heat gun tommorrow and see if I can't get it loose that way... this dang thing is on there!!



Yes... I did get the thermostat... ended up getting it from my local dealer for $28. 00... Cummins NW wanted 50 something for it!!!



I don't think that it is a 1/4"... the 3/16" allen fit snugly... the 1/4" allen is for the pan bolts. .

 

[rrausch]

The Mag-Hytec drain plug only needs to be snugged up. The torque for the plug is very low. I'll find out what it is, but it is LOW. The first time I drained my pan, I torqued it as much as I could with an Allen wrench, and MAN alive was it tough to get off at the next change. Now I just snug it up, and it comes off OK. It is so well engineered it doesn't neet a lot of torque to stay put.

 

[Bob Wagner]

you are correct

 

[Teacher]

Had the same problem a few days ago. Before I took action on the plug I ordered a new one in case I ruined it.

My local mechanic tacked a nut on the plug and wrenched it off. I now have two plugs!

Mag Hytec suggested I tap a small hole in the middle of the plug, then tap it at a 45 degree angle to loosnen it. Didn't do that!

 

[Snow man]

The torque is only 30 inch lbs! Do not overtighten it! You will never get it off.

 

[DLBurns]

If I can get the F*^(*& thing off!!!



The plug has never been out before, so I guess it came this tight from Mag HyTek??



I'm gonna drain some of the trans fluid out via the port for the pan temp probe ( if I can get that plug out ) and then take the pan off and see if I have better luck getting it off when it's off the truck...



When I do get it off, you can bet it won't go back on without a good coat of anti seeze on the threads!!!



A simple job turns into a PITA, isn't that always the way!!

 

[DLBurns]

Originally posted by Teacher

Had the same problem a few days ago. Before I took action on the plug I ordered a new one in case I ruined it.

My local mechanic tacked a nut on the plug and wrenched it off. I now have two plugs!

Mag Hytec suggested I tap a small hole in the middle of the plug, then tap it at a 45 degree angle to loosnen it. Didn't do that!

Your kidding

drill a hole in a perfectly good plug??? I have had to deal with things being a little tight before but this is rediculous...

The thing that PO's me is that now I have to deal with changing my trans fluid the "conventional " way... . getting fluid all over everything by loosening the pan bolts



Your idea about getting another drain plug is a good one... . gonna do that, because one way or another this dude is coming off!!!

 

[DLBurns]

OK folks... . got the fluid changed!!

Had to drain the pan through the port for the pan temp probe, took the plug out and transmission fluid shot back onto the skid plate Got fluid all over everything Got most of the fluid out and took off the pan... spilled the rest of it

put another container under the trans so that the residual fluid would leak into it... about a 1/10th of it hit the container

Took the pan over to the workbench and heated up the inside around the plug bung with my heat gun... corkscewed two more allen wrenchs and leaned my arm onto the heat gun

screw the plug... . went back to truck and drained the TC through the drain plug on it... that actually came out like it was supposed to Changed out the filter, put a new gasket on and reinstalled the pan. . Filled with 14 quarts atf fluid and test drove... . all good!!



Lessen learned: after a broken allen wrench, two corkscrewed allen wrenchs, a new brand on my arm, a trans oil stain on my driveway to remind me of this nightmare and more cuss words than a drunken sailor in Olongapo City... ... ... ... ... .



Hire someone to do this next time!!!!!!!!!!!!!

 

[Bob Wagner]

sorry about the problems, when the system works as designed its a real pleasure.



great reading

 

[DLBurns]

Originally posted by Bob Wagner

sorry about the problems, when the system works as designed its a real pleasure.



great reading

If that F(*&^ing plug would have come out... it would have been a piece of cake!!!

I will let whoever I pay the next time deal with that damn plug!!!

 

[rrausch]

The first time I changed the trans fluid I spilled a bunch and was worried it would stain the brick and concrete. Nope! Quite to the contrary, trans fluid just seems to seal it good!

 

[BPINE]

Sorry to here about your troubles Dave that is certainly not what we are striving for when we upgrade our truck. Sometimes these trucks can really be a PITA.

 

[Forrest]

uh oh ... wonder what i'm gonna find when I try the rear diff cover drain plug.

 

[rrausch]

Buff, who installed your transmission pan?

 

[DEZLPWR]

Same problem here...

But with my front Dana 60 cover... I ended up having to remove the whole cover to change the fluid. Kinda defeats the purpose of the $265 cover, eh? The plug had never been removed before, so it came from Mag Hytec that way. I destroyed 2 allen wrenches (one regular and one Craftsman socket) in the process. I called Jerry @ Mag Hytec, and he suggested the same thing, and that I should also buy another one from him for $22 just in case I damaged it when trying to remove it! This was all said without even once offering an apology. I wasn't satisfied with Jerry's answer, so I called up trusty Piers, whom I bought it from, and he sent me a new drain plug free of charge and told me that he would settle things with Mag Hytec at a later date!

Piers is first class all the way... Oo.

 

[DLBurns]

The transmission pan was installed when I had the Suncoast TC & VB done... I assume that the plug came installed from Mag HyTek?

I got an email from Jerry today and he said to call him and he would walk me through it using a hammer and sharp punch And I should get an order going for another plug!

So what I am understanding is, you have to destroy the original plug to get it out and then pay for a new one... hell of a marketing scheme.



Don't get me wrong, I'm just a little PO'd right now. I really think highly of the product, and if it worked as intended the process would have been painless. Just think that they could put some anti seeze on the plug when they install it so it doesn't bind up so bad.



I'll just buy another plug in two years when I do the trans fluid change out again... . I will however be looking for another pan if I have to destroy this one to get the damn plug out