Transmission fluid filler bolt rounded off!

[deejay1272]

After spending all day tinkering with other things on the Ter-junk-en, I decided to finally do what I know is good for the transmission: change the gear oil. Unfortunately I found the filler bolt to be totally rounded off. Of course I discovered this only AFTER I had already drained the old oil ! My solution was to chew ~10 pieces of gum, wrap it around the filler tube and actually pump oil into the transmission through the exit hole (genius, I know). You can imagine that this was not terribly successful or enjoyable. As a result, I would estimate that I'm approximately 0.5 quarts low on my gear oil.

Here's my question: Does anyone see any major problems with running the car (lots of freeway driving) with things in this condition?

Thanks in advance from a very tired T4WD owner.

[teranfirbt]

Half a quart probably won't hurt anything.. If you know anyone with a welder, have them weld a BIG nut to the filler cap, I've done it a couple times. The heat from the weld helps get the threads a little looser too.

[ARCHINSTL]

https://tercel4wd.com/forums/viewtopic.php? ... ler#p29548
You can fill from other plugs (lift the front up a little) - but read the preceding link first - plus the other threads about filler plugs.
Fill it and then drive it - these transmissions are too precious to throw caution to the winds.
You might try a BIG Vise-Grip on the rounded plug.
Tom M.

[xirdneh]

on the early models the plug is easy to see and is not partially shielded like the later models
i've used a long drift punch (i guess thats what its called)
its like a nail set but longer
hammer it into the side of the nut a bit until it digs in a little
then hammer it in the direction that will loosen the nut

[takza]

I TYPICALLY drain from all 3 drain plugs...then with the car on ramps (front) put 4.1 quarts into the FRONT filler plug near the driveshafts...problem solved....then retighten the rear drain plug that is still 7-8 turns out.

[Petros]

I have also filled from the front filler plug on the side of the diff housing. When you put the front end on ramps this one is easiest to get at, and it does not drain back out all over you before you get the 4.1 quarts in it.

Running a short time a half quart low will not harm anything, but get that last bit in from the front filler on the side of the diff.

[4wdchico]

A high quality 15/16" box wrench might get it off as it is around .007" smaller than a 24mm wrench.

[teranfirbt]

Always use a 6 point wrench on these.

[splatterdog]

Always use a 6 point wrench on these.

Better yet. Use a socket that has been ground/filed nice and flat, so that the inside wall is flush with the end. This gives you full engagement.

Worst case, weld a nut to it.

[Petros]

Worst case, weld a nut to it.

I would say worst case, leave it. And use one of the other two filler plugs.

You have a "worst case" when all three filler plugs are stripped. Than pull the trans and drill them out, and put ones in that you will not strip (allen wrench plugs?)

[splatterdog]

Pull the trans and drill? Pretty labor intensive for a stuck bolt. I've gotten broken little 6mm bolts out by welding. That big filler bolt would be a piece of cake for anyone that can weld without making bird poopie.

Otherwise just use the non stuck filler hole like petros said.

[deejay1272]

use one of the other two filler plugs.

I haven't tried putting gear oil in either of the other two filler plugs, but perhaps I'll try this.