That's a huge help Phil. I did wonder why it was like that.. gives me a better idea of how to tackle it today . Thankyou...

As mentioned earlier, I have hammered a torx or spline bit in before to undo rounded Allen bolts
I also always have a supply of the reinforced cut off wheels for my dremel which are great and as a last resort you could use them to remove the bit of casing shown in Phil's photo and then mole grips.
I think if the torx bit failed I'd be mig welding it in place or suck the oil out from the top using an oil vacuum thing.

I've ordered a 9mm spline socket. Will try that once it's here. It's my mates fatty and he's blaming the last owner for rounding it.. I don't believe him. Reckon he's been dabbling again lol..

Good stuff, i was thinking your drain plug was engine and not gearbox which is another thread I am sticking my oar in so I don't think sucking the oil out from the top is a good idea unless you want to drill a hole in your floor

Success! Rammed the spline in and it cracked.. gearbox serviced.. oil was really dirty looking.. there was swarf on the magnets.. is this normal or to be expected of a 12'year old car?

Top job.
Mine had a fair bit of magnetic fluff but turned out to be ok when we stripped it down but RRPhil is you man for that question of course, he can probably tell you what blood group the bloke that assembled the transmission has

Well done on getting the filler/level plug out!

If those magnets have never been cleaned before then you have nothing to worry about.

This is when you need to worry :

Click image to enlarge

Click image to enlarge

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It's the gearboxs first service so delighted with that. Glad they weren't like that.. thanks for input gents

Only concern was only being able to get 5 and a half litres back into box ? I did the service as documented?

As long as you had the engine ticking over and the fluid was at 40°C when you set the level then 5.5 litres should be fine. The torque converter and valve body assembly retain a lot of fluid when the sump is drained. Are you concerned because you drained more than 5.5 litres out, or because you’ve read that the transmission’s capacity is nearly 10 litres?

Phil

Hi Phil. I was only concerned as I had misread it would take 7 litres. I presume the 10 litres is from dry? Would you recommend maybe draining another 2 litres out after a certain amount of miles and refilling with 2 litres fresh fluid? Ta

I did a calculation once. Mathematically you have to do @ 5 changes to "change" 99.99% of the oil

Cost @ £90 if you buy in bulk. .
Experience is the only genuine knowledge, but as time passes, I have forgotten more than I can remember
Volvo V70 P2 2006 2.4 Petrol 170bhp Estate SE
MG Midget Mk1 1962

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