Technical Gearbox hell

[Baglady1990]

I’m in a world of pain ..of my own making!
I decided to change my gear oil this morning and I must have turned the plug the wrong way!!! The drain plug that is as it’s now inside & behind the thread…
So… what are my options!? I cannot get anything on the plug to retrieve it ..obviously I cannot leave it just rattling around and stick a new plug on
Is it a gearbox out job? As my gearbox was or seemed to be making noises when hot .. I think the fork bushings were dry as pushing on the clutch gave a horrible grinding noise and it’s definitely coming from the gearbox

So p off but I’ve put myself in this situation so now I just have to deal with it!

 

[varesecrazy]

Oh no..

I find it odd you could wind it in.. thought it would be tapered

Look for the GUIDE on the gearbox rebuild by Ash.. @whitz .. might be in cinq-sei.. or maybe misc

Its possible removing the tin cover would be enough.. sorry not done that much g.box work..


On the brightside.. you have oil and a catch tray handy

 

[varesecrazy]

Link:

the stripdown | 5 speed fire gearbox strip-down

The first thing you will want to do is remove the gearbox selector unit, remove the 5 13mm bolts after removal After this you will need to remove 7 10mm bolts that hold the tin cover on at the end of the gearbox Now you will have to knock...

www.fiatforum.com

You should have a chance with the gearbox still in the car ( although..of course.. not much room in a 500 )

Ash's guide seems to show an aperture down which you could pass a magnet..
Once the gearchange panel is removed.

 

[chris3234]

Are you able to get the Allen key into it still?
Could be possible to glue into the key and wind it back through if the glue gives enough stick to pull it back while you get a few turns on to it?


Guessing not however probably fallen down deeper inside the box?

 

[Baglady1990]

Are you able to get the Allen key into it still?
Could be possible to glue into the key and wind it back through if the glue gives enough stick to pull it back while you get a few turns on to it?


Guessing not however probably fallen down deeper inside the box?

Not a bad idea at this point I’ll try anything been trying to grip the inside with a large pair of tweezers!
No it’s still near the opening…it doesn’t appear it could drop down anywhere… as trust me it would have by now!

 

[chris3234]

Are you able to get the Allen key into it still?
Could be possible to glue into the key and wind it back through if the glue gives enough stick to pull it back while you get a few turns on to it?


Guessing not however probably fallen down deeper inside the box

Not a bad idea at this point I’ll try anything been trying to grip the inside with a large pair of tweezers!
No it’s still near the opening…it doesn’t appear it could drop down anywhere… as trust me it would have by now!

If there's not too much oil around a few drop of super glue on the front face of the Allen key may give enough hold for you to wind it back in with some luck

 

[Baglady1990]

Are you able to get the Allen key into it still?
Could be possible to glue into the key and wind it back through if the glue gives enough stick to pull it back while you get a few turns on to it?


Guessing not however probably fallen down deeper inside the box

If there's not too much oil around a few drop of super glue on the front face of the Allen key may give enough hold for you to wind it back in with some luck

I’m gonna need a lot of luck with this! Jesus I can be so thick at times!!!

 

[Baglady1990]

Are you able to get the Allen key into it still?
Could be possible to glue into the key and wind it back through if the glue gives enough stick to pull it back while you get a few turns on to it?


Guessing not however probably fallen down deeper inside the box

If there's not too much oil around a few drop of super glue on the front face of the Allen key may give enough hold for you to wind it back in with some luck

You absolute LEGEND it worked!!!! Used wide tweezers to centre the plug and get it to the thread… that took most of the day!
Then gently superglued the hex into the plug left it an hour then while I crapped myself.. gently worked the plug back in …

Oil now in & no leaks whatsoever!
Thank you Chris I would never have thought of glue!

 

[chris3234]

You absolute LEGEND it worked!!!! Used wide tweezers to centre the plug and get it to the thread… that took most of the day!
Then gently superglued the hex into the plug left it an hour then while I crapped myself.. gently worked the plug back in …

Oil now in & no leaks whatsoever!
Thank you Chris I would never have thought of glue!

Good to hear the suggestion worked saved you a lot of work and possible expense

 

[IanWard]

Good save, sounds like a nightmare scenario

 

[Baglady1990]

Good to hear the suggestion worked saved you a lot of work and possible expense

Yup

Good save, sounds like a nightmare scenario

still learning! Needless to say ..won’t be making that mistake again!

 

[Ralf S.]

The car was probably thinking.....


Ralf S.

 

[Baglady1990]

The car was probably thinking.....


Ralf S.

Never mind the car … I was looking for rope! & a suitable tree

 

[TrevC]

Yup

still learning! Needless to say ..won’t be making that mistake again!

It does beg the question though - if you remove the drain plug correctly and drain the box, how do you know when you have screwed it back in enough, if it will just keep going all the way? Does it rely on the thread for a seal? Am I missing something?

 

[Baglady1990]

It does beg the question though - if you remove the drain plug correctly and drain the box, how do you know when you have screwed it back in enough, if it will just keep going all the way? Does it rely on the thread for a seal? Am I missing something?

Well .. obviously your not supposed to do what I did it started flush .. and I was wondering why it didn’t seem to be coming out! I’m lucky I didn’t crack the gearbox!!!
Well no leaks maybe I was lucky .. it was very tight .. no wonder I was tightening not undoing

 

[A3jeroen]

The stuff nightmares are made of

gr J

 

[chris3234]

It does beg the question though - if you remove the drain plug correctly and drain the box, how do you know when you have screwed it back in enough, if it will just keep going all the way? Does it rely on the thread for a seal? Am I missing something?

Just the tread to hold the oil it it seems


As for the how for to screw in I'd say just until it's about flush with the surface

Although of thin bead of thread sealant on the outer most threads wont go amiss

 

[Baglady1990]

Yeah I’ll keep an eye on the plug … it’s holding as it should though so should be ok got a new plug too just in case …

 

[Baglady1990]

The stuff nightmares are made of

gr J

Yeah! But I got it sorted! 4 hours later and I’d gone cross eye 👁

 

[A3jeroen]

I just keep thinking about the John Cleese movie Clockwise

gr J