SpokaneSpyder

And I mean STUCK! couldn't get my impact wrench to move it.
Thanks goodness I didn't drain the tranny fluid first and THEN find out the fill plug was stuck closed!!!

Has this happened to anyone else? Any suggestions on what to do?

slow ride

Heat the area with a map/propane torch.

SpokaneSpyder

I assume map doesn't get hot enough to melt the aluminum?

donromani

It shouldn't, no. You really just need to get it hot enough to expand a bit then you try to remove the plug again. Repeat as often as necessary.

If that doesn't work there are other ways to fill the tranny up. You can remove the big "bolts" along the top of the tranny, I don't know what they are called but I've used those before with a long hose snaked up to the engine bay to refill.

I've also had luck using pb blaster on a stuck bolt and waiting a day or so then trying again.

bikenut

the torch won't do any damage, just don't catch the CV boot by accident or anything. keep that torch on there for awhile, get it nice and hot and also PB it. it won't damage the metal. use a breaker bar,and slip your floor jack handle over the breaker bar if needed...