Greetings fellow Jaguar fans ;o)

Had the back end of the car nicely jacked up and on stands
with jack still in place as added security.
First, grease all the UJ grease nipples (zerks) which were over due.

While the car was jacked up so high, it allowed me to go
further forward and check out the filler plug for the gearbox.
This is supposed to be an 8mm Allen socket but after testing 3 or
4 different tools found that they were all a sloppy fit.

Closer inspection revealed that some ham fisted clot had
been using a tool at an angle and had munted the hole!!
Dam!! I hate butchers!! I cannot understand for the
life of why some one would need to tighten it so much!
The worst thing is these are an alloy plug....awkward to get
to and you need the correct Allen key or socket of the right
length to get a direct inline fit.

Right sez I, the hole has been butchered which means
anything 8mm is not going to fit tightly to get enough
purchase on it.
Plan 'B', get a Torx bit a couple sizes up and bash it into
place to form new grip.....the big problem is getting it
straight as 'direct line' is partly shielded by the chassis.
The plug of course is now completely ruined and I need some
thoughts on removal.....I'd appreciate any help on this ;o)

To get at it properly, I am going to have to remove the
front exhaust section and possibly undo rear g/box mounting
and lower just enough to work on the damn thing comfortably.
I thought about using a cold chisel but that's a bit canibal
like.
I have also thought about drilling two holes oposite each
other to insert pins to which I can either fashion a tool
to fit or use a large screw driver against the pins.

Any more ideas??

 

As you said, making enough space is the first thing to do.

I would take an allen key which just doesn't fit and grind it to size to make it a perfect fit. This means you have to take your time and try-fit more times than actually grind material off. Once done you can put force on it.

A torx bit may be the way to go as well, take one which barely fits and hammer it in. Can be you have to slightly machine that one to size as well.

 

I thought the plug was steel. Your ideas for removal sound practical, as the exhaust is definitely in the way.
I would try heating the alloy housing to ease removal. I have noticed that it's easier to break the plug loose when the transmission is up to operating temp., so applying heat should help.

 

RJ....you could be right, I need to check with a magnet but I was of the understanding that they were alloy.

 

Nick....I'm still leaning towards a modified Torx bit, especially a six point
which should bite into the metal and then use a 3/8 drive rattle gun.
If that doesn't work, it's drill a hole and fit an Ezy-Out....unless of course the plug turns out to be steel, I could weld the key to the plug....or as some one has suggested Epoxy the key in place.
More thinking to be done ;o))