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Old 10-01-2012, 12:11 PM   #1 (permalink)
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Angry Manual Transmission drain and fill plugs

Hey all. Went to change the gear oil in my 92 2wd 5sp Tracker and lo and behold..The oil fill plug is buggered to the point of being impossible to get out using conventional tools. Luckily I had checked the fill plug BEFORE draining he gearbox... So, I called my local Chevy dealer's parts dept to see of they had or could get me a new drain and fill plug and was told they were discontinued from them.. So..what to do? Are these plugs a common size I ought to able to get aftermarket at a parts house?

Thanks for any ideas or info you might have

Regards

John
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Old 10-01-2012, 12:17 PM   #2 (permalink)
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Quote:
Originally Posted by John Mitchell View Post
Hey all. Went to change the gear oil in my 92 2wd 5sp Tracker and lo and behold..The oil fill plug is buggered to the point of being impossible to get out using conventional tools. Luckily I had checked the fill plug BEFORE draining he gearbox... So, I called my local Chevy dealer's parts dept to see of they had or could get me a new drain and fill plug and was told they were discontinued from them.. So..what to do? Are these plugs a common size I ought to able to get aftermarket at a parts house?

Thanks for any ideas or info you might have

Regards

John
I think they are just pipe plugs..,,, take your fill plug and match it up, pretty sure drain is same size... and i think "pro's chime in if i am wrong" the front/rear dif use same size plug..
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Old 10-01-2012, 12:30 PM   #3 (permalink)
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The plugs should be available from SouthWest Suzuki Motors - p/n 09246-16010 - around $5 each. The reason they get that way is people use a 3/8" square ratchet handle on them rather the correct 10mm square drive wrench.

dustwatts - the diff drains are the same, the fill are different.
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Old 10-01-2012, 12:40 PM   #4 (permalink)
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If removing is the issue, insert a standard bolt into the 10mm recess(hex head out) and weld it solid. Then use a socket to remove and reinstall.... Philip
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Old 10-01-2012, 03:59 PM   #5 (permalink)
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Thanks guys for the timely answers!
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Old 10-01-2012, 07:26 PM   #6 (permalink)
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What Aquanaut20 said.
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Old 10-02-2012, 01:06 PM   #7 (permalink)
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i brought mine to fastenal and got stainless bolts n put them in.
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Old 10-02-2012, 11:06 PM   #8 (permalink)
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I bought replacements from NAPA. They sell square head ones. Not recess square like allen head but sticking out. I think they are made of brass.
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Old 10-03-2012, 07:28 AM   #9 (permalink)
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Quote:
Originally Posted by trackerER View Post
I bought replacements from NAPA. They sell square head ones. Not recess square like allen head but sticking out. I think they are made of brass.
I think Permatex makes a thread sealant with properties to prevent corrosion between dissimilar metals.
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Old 05-22-2013, 03:40 PM   #10 (permalink)
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Quote:
Originally Posted by fordem View Post
The plugs should be available from SouthWest Suzuki Motors - p/n 09246-16010 - around $5 each. The reason they get that way is people use a 3/8" square ratchet handle on them rather the correct 10mm square drive wrench.

dustwatts - the diff drains are the same, the fill are different.
Yeah so here's the difference between all these work arounds; the OEM p/n 09246-16010 is now made of steel, has a magnet, and has the green thread protector. My original plugs are made of aluminum and are junk. Looks like they upgraded these since 1991. I got the last 2 from oemsuzukiparts.com p/n 09246-16010 is also used on the swift and old suzuki outboard motors.
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