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Can't remove gearbox drain plug

in 2 Stroke Technical Questions 11 years ago

  • Re: Can't remove gearbox drain plug

    by » 11 years ago

    Mike,

    Being softer, the copper makes a much better seal without exceeding the torque limits. There aren't many threads in that drain hole and it would be easy to distort or strip the threads by overtorqueing. Although the book doesn't say so, that particular plug is a wet torque situation and can be stripped much more easily than a dry bolt and dry hole.

    Bill.
      
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  • Re: Can't remove gearbox drain plug

    by » 11 years ago

    Read the Magnetic plug thread in the 4 stroke section......similar situation.....
      
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  • Re: Can't remove gearbox drain plug

    by » 11 years ago

    I have not been successful in removing the plug. I heated the gearbox around the plug today with a propane torch. I also applied Kroil several times prior to heating it. I am concerned about ruining the threads. I'm not sure what else I can try. I can put a pipe over the wrench to make a longer handle and get more torque on it.

    Removing g the prop (3 bladed composite Warp drive prop) would make easier access but I don't know the torque value and Warp is not answering my email. Their customer support leaves a lot to be desired.

    I have received the new drain plug and will replace the current one if I ever get it out.

    Is the plug steel? Might it be seized to the aluminum threads of the gearbox?
      
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  • Re: Can't remove gearbox drain plug

    by » 11 years ago

    Mike,

    Torque for a warp drive on a rotax hub is 175 inch/pounds.

    The plug is steel.

    Sounds like the threads are already galled. Only thing to do is put the pipe on the wrench. It is best to use a socket or closed end wrench. Better yet, use a six point socket with a long pull bar. If you have access to a pneumatic wrench, that will zip it right out. Your local auto tire store could have it out in two seconds. There is enough meat in the gearbox to allow you to retap and go one bolt size larger with a new plug. This is done more often than you might think.

    Bill.
      
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  • Re: Can't remove gearbox drain plug

    by » 11 years ago

    Bill, what does "galled" mean?

    I did get a 6pt wrench. Looking for a piece of pipe now.

    What about removing the gearbox from the engine? Is the gearbox case one piece, or two that can be separated?

    As far as your last thought goes, although I have a lot of pilot time, I've got zero mechanic time. To retap it, I would have to remove it because it sits so close above the root tube that I could never retap it without removing it. And my biggest fear is that, as I separate it from the engine, something will fall out of the gearbox and I won't have a clue how to put it back.

    I am not against retapping it. In fact, I think it would be a good learning experience. However, I would need a "Plan B" when it failed, NLOL!

    For right now, as long as I can remove the lower level screw, (which I haven't tried yet) I can add oil to make sure the level is ok. But that would just be temporary.

    I am planning to fly from NJ to VA at the end of the month and I could work on the plug when I get back.
      
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