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92 240 transm bolt stripped and can't come out--tap it out is best? 200


my 92 245 tranny drain plug is stripped and just turns in its hole, i guess the threads in the pan are stripped.

it was barely leaking when i bought it back in sept 2004, and i first thought it was a seal.

i tried to tightened it but whoever worked on the fluid last tightened it enough to hide the leak.

i want to avoid taking the pan off and that ridiculous fill tube.

i thought about this:
a) tap the damn drain bolt out with a drill bit (bolt=14 mm),
b) use a strong magnet to try to remove remaining metal particles, (magnet on the outside and draw the particles to the hole and out),
c) retap the hole with a larger bolt size.
d) and hope that it works.

any problems with this way? read a version of this method in FAQ.

any suggestions/precautions?

thanks as always!
byron golden
86 245
92 245








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    92 240 transm bolt stripped and can't come out--tap it out is best? 200

    If the pan is sheet metal there won't be enough meat to retap.
    If the pan is sheet steel, you will have to put the magnet inside
    to get the particles as soft steel is fairly good magnetic shielding.
    Probably the best bet is to get a pan off a dud tranny.

    You wouldn't have this problem with an M46, etc.
    --
    George Downs Bartlesville, Heart of the USA!








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      moot--drilled too far, got pan threads; anybody have a aw71 tranny pan? 200



      Thanks everyone for the fast replies.

      it's a new topic now.

      regards,
      byron








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    92 240 transm bolt stripped and can't come out--tap it out is best? 200

    That and some grease on the tap will work fine. All the chips and debris will either be removed or will remain in the bottom of the pan for life.








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    92 240 transm bolt stripped and can't come out--tap it out is best? 200

    sometimes you can get a stripped bolt to come out by pulling on it as you turn it - like - loosen the bolt, put a pair of vise grips on the bolt head (let the jaws of the vise grips engage the bolt head so that the vise grips are pointed down, not lined up parallel to the bottom of the trans case) and turn and pull down at the same time. there's an off chance the bolt itself is stripped and not the threads in the pan.
    if the pan threads are stripped, then you can decide to retap or whatever. i would as already suggested replace the pan though, because it's less work in the long run to do that, and do normal maintainance thereafter.








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      92 240 transm bolt stripped and can't come out--tap it out is best? 200


      thanks for the reply. i've tried to do just that--i was hoping that the bolt threads would "catch", but the bolt came out only a little more.

      i may try to tap it with increasing drill sizes but less enough not to touch the pan, then squeeze the bolt smaller.

      local junkyards don't like to take apart trannys, they want to sell the whole thing. i'll try this weekend.

      also, i've read in the archives to try to avoid removing the fill tube.

      regards,
      byron








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        92 240 transm bolt stripped and can't come out--tap it out is best? 200

        if the bolt comes out a little way, sometimes you can take a wood chisel and tap it into the gap that's starting between (in this case) the pan and the bolt head. you would get a quarter or a half turn then the chisel would work out, but you can keep at it.
        a garage that does a lot of volvo repair might have a broken transmission you could salvage a pan from. good luck with it.








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    92 240 transm bolt stripped and can't come out--tap it out is best? 200

    Two suggestions:

    Just put a new pan in it and be done with the darn thing.

    Do your trans services from the trans cooler lines at the radiator. Pop the top cooler line off, stuff a hose on the radiator side, pump a gallon out as you pour a gallon in.

    Mark








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      92 240 transm bolt stripped and can't come out--tap it out is best? 200


      Hi Mark,
      thanks for the reply. i was thinking that the fill tube would be too difficult to remove, unless i just get it loose so i can get it out from the bottom.

      regards,
      byron








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        92 240 transm bolt stripped and can't come out--tap it out is best? 200

        you are wasting your time. you will not get the plug out without removing the pan. the plug is junk,the pan is junk. remove the bolts from the bell housing that brace the dipstick and remove pan with dipstick tube attached. i have done several of these. the plug was over tightened and the threads are now above the hole. the more you try the more it will leak. get a used pan before you need a transmission. i do believe that i have a pan if you are in the pittsburgh area

        bob
        bis@forcomm.net








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          92 240 transm bolt stripped and can't come out--tap it out is best? 200


          Hello Bob,

          thanks for your reply.

          you're absolutely right. i tried to drill the hole out & "screwed" the pan.

          i should have never messed with the pan, just go get another.

          sometimes, we just work stupidly just to work on the 240, in my case it was.

          i did buy one last night, and thanks for your offer, too.

          that's how superb bb is, such fast help.

          regards,
          byron







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