Mate was changing the gearbox fluid in his 03-TD6,he loosened the fill plug and then proceeded to open up the drain plug to drain and take the sump off to change filter,etc.
After draining and putting filter/sump back on he proceeded to take the fill plug out but the previous person that serviced the g/box the plug when he put it back on. It wont come off.
Any suggestions on how to get the bolt out without up the already thread.
Then what would be the best way forward to get new bolt in without further up the thread anymore.
Any help greatly appreciated.
littecub

If you mean that the hex head of the fill plug has rounded off, I used a 17mm Irwin bolt extractor to remove mine.

There are kits available to repair, here’s a link to one on a popular auction site…

https://www.ebay.co.uk/itm/183101645081?mk...media=COPY

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Simon
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Range Rover Classic 3.5 efi - Gone
Range Rover Classic 3.9 efi - Gone
Range Rover Classic 4.2 LSE - Sadly gone
Land Rover 110 3.5 - Gone
Range Rover P38a 4.0 SE - Pleased it's gone
Range Rover P38a 2.5 DHSE - Just sold
Range Rover L322 4.4 v8 Petrol - Current

Looks like the filler plug will be a bit hard to reach, he may have to drop the box etc to gain access... Also you will need the sump off to clear swarf from recutting the threads, all in all not a quick or easy job...

Thanks Pete I see what you mean….not easy at all. ______________________________
Simon
______________________________

Range Rover Classic 3.5 efi - Gone
Range Rover Classic 3.9 efi - Gone
Range Rover Classic 4.2 LSE - Sadly gone
Land Rover 110 3.5 - Gone
Range Rover P38a 4.0 SE - Pleased it's gone
Range Rover P38a 2.5 DHSE - Just sold
Range Rover L322 4.4 v8 Petrol - Current

Excellent for the drain plug which is the most commonly abused one...

Never seen that kit before, mind you, luckily never had a problem with a drain plug...  Pete
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2014 L405 Autobiography SDV8 4.4 Loire Blue Ebony interior
2012 L322 Autobiography 5.0 Supercharged Ipanema Sand Sold
2011 L322 Vogue SE 4.4 TDV8 Baltic Blue. Sold
2002 L322 Vogue 4.4 V8 Epson Green (Fatty Offroader) Sold
-Click for Project Fatty off roader-

 ______________________________
Simon
______________________________

Range Rover Classic 3.5 efi - Gone
Range Rover Classic 3.9 efi - Gone
Range Rover Classic 4.2 LSE - Sadly gone
Land Rover 110 3.5 - Gone
Range Rover P38a 4.0 SE - Pleased it's gone
Range Rover P38a 2.5 DHSE - Just sold
Range Rover L322 4.4 v8 Petrol - Current

Thanks for the extra tips on how to get the hex off guys, much appreciated.

littlecub