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Old 13-06-2017   #1
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Gearbox filler

A completely seized gearbox filler any ideas from fellow fiat people on how to get it undone..
Or another filling method it is on a punto mk2 jtd has zero oil in but I don't really know if a blow torch would heat it enough to crack it and certainly don't want to crack gearbox in the process, which has just been replaced after third and fourth went walkies..
Ive tried breaker bar even a jack on a breaker for a few days..
It's had plenty of penetrating oil.
I believe a reaction between alloy and steel takes place creating said really annoying problem.

If anyone has some idea or the solution please help..
Forum has been v good so far some day I will be guiding others as car is practically rebuilt.
But this little sod is spoiling the day now.
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Old 13-06-2017   #2
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Re: Gearbox filler

Please post photo of part you are trying to undo
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Old 13-06-2017   #3
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Re: Gearbox filler

Is the reverse light switch at same level as filler?
Does your gear box have a breather on top ?
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Old 13-06-2017   #4
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Re: Gearbox filler

well you always come to my rescue cheers bud... But can post some helpful info instead of asking for once..
Removed reverse sensor as yes it was the filler I was struggling on with tried everything then...
A sudden strike of intellect I grabbed my giant gas bottle and burner, heated her gently... Bearing in mind no oil in as it's a replacement box... Squirted some knock of wd on it while hot..
I believe the heat may have done it but I would think the expansion contraction also helped...
Bear in mind I got a very wet rag and covered the bay and avoided gearbox sensor..
Didn't go mad on heat and centered on the steel filler bugar nut Allan key, I actually used hex as it's all I had.

Honestly no force necessary to undo.

Blow torch my new friend.. Actually thought it was gonna need acycetaline as that's what I've seen mechanics use on low obviously I'm not talking cutting lol.

But thanks jackwhoo for enquiring yet again.
Gotta love that fiat naughtiness.
Lol no it happens in all cars.
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Old 13-06-2017   #5
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Re: Gearbox filler

Well done,
It's the differential expansion between alloy and steel that does the trick with heat.
I was going to suggest a hot air paint stripper as less likely to cause damage than a blowtorch, but you've done it OK.

Robert G8RPI.
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Old 13-06-2017   #6
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Re: Gearbox filler

cheers dude yeah defo the heat but I wonder if it wicked the wd in,
now it's operation horn I did have a rather shonky but operational horn that sounded a little bit mouseified quite odd...
I know the terminals get crusty and I've been cleaning them up just seems that it's not getting power.. Now I've looked at fuse 10 or 12 whichever it is under bonnet is fine..
I had an old and tragic air horn, not the dukes of hazard job that had been laying outside.. Across a battery no go clearly furred up took three screws out the end cleaned it up nice.
Filled it full of wd knock of ( interestingly the nozzle from the fancy wd one fits on, that swivels... Pound land maintenance spray were talking.. Anyway horns happy on 12v supply with all wd spraying out it would of made a stunning flame thower lol.. Noisy to.
Not much good without power though.
I'm quite sure it should run on a relay..
But no power seems to be getting to original horn wiring..
More investigating needed..
It has hgt steering wheel fitted many moons ago when "rockbottom" that was a member here had it fitted.
Multimeter time me thinks or perhaps a bodged into dash switch or something..
Be nice to have it working as it's meant to though...
lol the hours it's had out of me fitted a alloy momo strut brace today no holes to drill looks well.
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Old 13-06-2017   #7
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Re: Gearbox filler

Quote Originally Posted by dubsential View Post
well you always come to my rescue cheers bud... But can post some helpful info instead of asking for once..
Removed reverse sensor as yes it was the filler I was struggling on with tried everything then...
A sudden strike of intellect I grabbed my giant gas bottle and burner, heated her gently... Bearing in mind no oil in as it's a replacement box... Squirted some knock of wd on it while hot..
I believe the heat may have done it but I would think the expansion contraction also helped...
Bear in mind I got a very wet rag and covered the bay and avoided gearbox sensor..
Didn't go mad on heat and centered on the steel filler bugar nut Allan key, I actually used hex as it's all I had.

Honestly no force necessary to undo.

Blow torch my new friend.. Actually thought it was gonna need acycetaline as that's what I've seen mechanics use on low obviously I'm not talking cutting lol.

But thanks jackwhoo for enquiring yet again.
Gotta love that fiat naughtiness.
Lol no it happens in all cars.
Oh hello !

That's put me down for sure.

If reverse light switch same level as filler plug you could have left filler plug and filled through reverse switch hole.
it often works out on many different makes that is the case.

Breather question - if you have breather on top of box, it's easier and less messy and more accurate level wise to fill through breather.
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Last edited by jackwhoo; 13-06-2017 at 18:16.
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Old 13-06-2017   #8
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Quote Originally Posted by jackwhoo View Post
Oh hello !

That's put me down for sure.

If reverse light switch same level as filler plug you could have left filler plug and filled through reverse switch hole.
it often works out on many different makes that is the case.

Breather question - if you have breather on top of box, it's easier and less messy and more accurate level wise to fill through breather.


Cheers bud I got the plug out so at least I can see I put enough or not to much in...could of measured it out I guess..

Handy tip though would of stopped me messing around with chisels, hammers, jacks breaker bars I'm getting myself a nice plumbers torch.. Much handier.. I think we will make good friends lol.
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Old 13-06-2017   #9
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Quote Originally Posted by jackwhoo View Post
Oh hello !

That's put me down for sure.

If reverse light switch same level as filler plug you could have left filler plug and filled through reverse switch hole.
it often works out on many different makes that is the case.

Breather question - if you have breather on top of box, it's easier and less messy and more accurate level wise to fill through breather.

Don't suppose ya got any ideas on the horn issue I mentioned above in this post, maybe should of started a new thread but hey..
You seem to know your stuff. Have you a jtd?
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