Transmission drain plug stuck

[BruceMerc]

Doing my 1st maintenance on my 2008 Mastiff with just under 1500 miles on it. Oil filter was tight, I bent my old wrench so I needed the strap type to remove it. After changing the motor oil I moved on to the transmission and found the transmission drain plug not being very cooperative. On my bike the oil lines are run outside the frame and makes it real tight near the drain plug (angles the Allen wrench). Plug is tight and I don't want to strip the head. I assume that it is a 3/16" Allen because the 5 mm metric is too big but the 3/16" has some play. Has anyone tried using a pump to remove the oil or is the drain the only way? Any suggestions would be appreciated?

Thanks,
Bruce

 

[boomer4444]

could always pull top tranny cover off and syphon fluid out, i believe its 6 bolts of differant lenghts,,after changing my tranny fluid i cant stop the f-n dripping from the plug, tried plumbers tape etc no luck ,,,20 oz of fluid back in

 

[francoblay1]

I had the same problem as you.. oil lines in the way... I did use a piece of tube (like the one that runs from the Carb to the bottom of the bike) and sucked the fluid out via the filling hole. It takes awhile to drain but it works. :up:

 

[Ratman]

On my Mastiff I used the correct size Allen wrench but cut (I believe) about 1/2" off the short end. That way-I could move the oil lines over with my left hand a tad while getting the Allen wrench in at a perfect 90 degree angle. Good luck! And as bigdogtech01 lists below (I forgot to mention in my original post) take the clamp off. I had a heck of a time the first time I tried to take that plug out.

 

[bigdogtech01]

Remove the clamp that holds the 2 lines together. This will give you some play on the lines, but not much. Using a "ball" type allen with 3/8" drive and ratchet, you can usually remove and install the plug with no problems. The best thing to put on the plug before installing it, is the liquid type Teflon...not Teflon tape.
You can buy a small tube of it at most any automotive parts stores.
This is what I use.... Thread Sealants : Permatex® High Temperature Thread Sealant

 

[kickstart]

You can get these in different lengths, makes it a lot easier.

9 Piece 3/8" and 1/2" Drive SAE Hex Bit Socket Set

 

[Bobby Schulz]

Please make sure to use a good allen wrench. I have seen many striped out due to a low quality tool.

 

[BruceMerc]

I had the same problem as you.. oil lines in the way... I did use a piece of tube (like the one that runs from the Carb to the bottom of the bike) and sucked the fluid out via the filling hole. It takes awhile to drain but it works. :up:

Were you able to pull all 20 oz of the fluid out?

 

[francoblay1]

Were you able to pull all 20 oz of the fluid out?

Yup, all of it! :up:

Just be patient and also get someone to help you to lean the bike a little bit to the right when it is almost empty.

EDIT: I forgot to mention... for the very last drops I used a Syringe to pump them out.

 

[JeffM]

All of the above are all exellent ideas.
I would not use Allen type wrench, use a 3/8" socket type, ensuring it is the correct size.
Prior to that i would use a punch and hammer and strike the offending part 2 sharp blows, inset socket type (a tap into place may be required to ensure it is seated) then undo plug.
Take said plug to a local plug shop, purchace a hose tail with same thread, 2x hose clamps and 1 ft of black oil hose and make up a hose drain same as HD Evo and plug the other end.
As for sealant, use a product Loceal 58-11, it has a million uses and can do taps (fawcets ?) at home anything with a thread, use contact cleaner to clean both threads first. Thread tape was used in the last century not this one.

And good luck

 

[RoadRider]

Be careful tightening the plug with a ball allen. If you try to put to much torque on it , it will strip the head for sure. I cut an allen short so I can use it instead of a ball allen

 

[BruceMerc]

All of the ideas were good ones. The drain plug on my bike already has teflon tape on it, so it must have been removed once before and may have even been added to stop a plug leak. My fear was that the last owner overtightened the plug. I decided instead of taking a chance of striping it and then having to drill it out I used a "turkey seasoning type injector" with a small vinyl air line used for aquariums attached to it. I used this to extract the fluid out of the transmission. It took a while but at least it is done and with no damage. Thanks again for all of the suggestions and ideas.