Hey don't think your problem is too unlike a professional mechanic's issues.

Problems like that are pretty normal with older vehicles; but a pro has more tricks to deal with stuff before he has to call in the calvary.

I myself am pretty darned good with anything mechanical, construction or engineering wise. I am even a bit of a legal beagle and a Dr. health type.... But that does not mean I do not seek outside help from a lawyer or Dr or any other professional when I get in over my head. I really hate hearing the nay sayers quickly jumping on the don't try that yourself band wagon. Just because someone else does not think you are capable does not mean you are not!!!!!!!!!!!!!!!

 

Thanks

I spoke to my Porsche mechanic, he told me that he has many customers that try to DIY on their cars and it ends up costing them a lot. I wonder what is he going to charge me to take the plug out...
In the future I will first set up the car higher on jacks because it felt like I was hugging the car from underneath... And I will clean the plugs/bolts and maybe use some lubes or the hot water trick.

 

I reach for the blow torch way more often then I use hot water, it is way more convenient and many things require more temp.

Hot water is great for areas around seals or other more sensitive components, or for things like stators and flywheels.

 

My suggestion if its aluminum, go to your local welding shop, weld a small piece of metal to act as a handle to unscrew it. Ask about warping issues before hand. I had something similar before but on a different car and it unscrewed. $20 bucks for a quick few tacks of weld and the metal.

 

Quality tools definitely help. Not all allen keys are made to the same fit. Some fit more loosely (which obviously is not good) and some fit very snug. There is a reason why snap-on stuff cost an arm and leg.

But in the case of stuck bolts/nuts, an impact wrench is your best friend. I have both an cordless electric DeWalt (takes off lug nuts and other bolts quite easily) and an nice air impact wrench for the serious stuff like axle nuts (the 996TT is torqued to 350ft/lbs if I remember correctly and the air tool took it off in literally 2-3 seconds).

 

My guess is at 22 lb/ft, even an average allen should have worked. Meaning - previous tech over tightened. But I agree - quality tools do help. Snap On, Hazet, etc.

 

Un-likely it was tightened that much, it is more likely a case of galvanic corrosion and numerous heat cycles. Also it very well could have been put back together with a hot tranny and a cold plug.... A real savvy tech lets parts like that temperature normalize before he torques.

 

Do you recall what thread size is required for the quick drain on the Cayenne and 996 turbo?

 

Don't feel bad, my first Porsche was 78SC. I didn't know much about it other than the engine was in the back. My first DYI oil change I slid under the back with my trusty Pep Boy oil pan a took off the plug under the engine, and to my shock only a little oil came out. I called a buddy who told be there was another tank off to the side with the oil in it. So I found the tank and pulled the drain plug and sure enough lots of oil came out. I mean lots and lots of oil which over flowed the drain pan and covered my parents driveway with oil. I spent a week everyday cleaning it off.

 

So I have had this happen on a number of allen bolts in other applications (valve seats on an old shower more than once) If the hex bolts stripped I had good luck with taking a torx bit one size larger than the allen and tapping it in firmly with a hammer. Get a good long wrench on it and you can usually loosen the bolt up and get it out.

I don't know that I have ever done this on an aluminum bolt (usually brass) the aluminum may be too soft to hold the torx bit in place, but if the damage is already done, I would have given it a try.

 

@Engine guy and f1crazydriver, I will let my mechanic (going on sat morning) try his tricks first. From what I understand he will hammer in a bigger bit. If that doesn't work first I think I'll panic, then maybe last resort would be really welding (I hope not).

@statepkt I should get an impact wrench, I saw they recently started making these kits of a drill and impact wrench (with Lithium Ion batts) and they are so small, light and powerful compared to the drill I have now.

@bbywu honestly I think it was over tighten before, plus not touched for a very long time (and pretty dirty). So the dirt ate the plug, plus I didn't clean it good, plus very tight fit and maybe not the best allen fit or it wasn't all the way in (my friend was the one who finally stripped it) = stripped. My mechanic told me that the transmission plug is usually a bit like a cone at the end of the thread, so the more you tighten it at the end the more pressure it applied on the sides.

@Duane996tt I had something similar with my motorcycle, but luckily it was on a bike stand so the cleaning was easier... Actually, it's still on the bike stand now waiting on some bolts from Honda.


@dailydriver I am debating on what to bring my mechanic to use, an oversized torx (11mm or 12mm? original is 10mm allen), or go with what bbywu suggested, the specialty Craftsman bits. I actually got the kit from Craftsman but I bought the wrong item, I got the kit that you drill before and then the bit makes a new thread in the drilled hole.

 

Urrg, I knew someone was going to ask. I have to look it up.

 

OP I am hoping your mechanic would have all the tools he needs to tap the plug and get it out of there. If you are needing to bring him tools to use, I think that is a red flag and you may want to consider a new mechanic.

 

Oh he didn't ask, I just figured I'll have one in case he doesn't have exactly the right size bit to tab into the plug. Since he told me the plugs that he usually gets stripped are the engine oil drain plugs and they are smaller.

 

Ok update: I ended up taking the Porsche to my Mercedes mechanic and he was nice enough to let me use one of his 2-post lifts and help me. Luckily the fill plug was only stripped about half way so the socket was still able to have grip at the end and it finally came loose.

After we took the fill plug off we were asking our selves if the torque pres is really 22lbs/ft for the plugs. Because whoever tightened those plugs before tightened it at lease double than that by the force that was needed to loosen them.

Plus the tranny drain plug had a washer but the fill did not have a washer, although it seemed like it should have one.

I replaced both the fill and drain plugs with new ones and washers.