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Removing magnetic plug from Rotax 912 gearbox

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Richard Lamprey

Joined: 15 Jul 2011
Posts: 95
Location: Kenya

Posted: Sun Feb 19, 2012 12:49 am Post subject: Removing magnetic plug from Rotax 912 gearbox

Does anyone know the best way to get this plug out?  I burred the hexagonal inset, so hex key (allen key) no longer going to get it out.  I have tried clonking gently with hammer (as per various instructions) to loosen, to no avail.



My plug replacement is of the new variety that can be removed with a ring-spanner.  Just got to get the old out and check for filings.



Perhaps a left handed thread bolt/screw that self-taps into the burred inset??



Any ideas welcome.

Richard

Europa 168, Kenya

ward.t(at)xtra.co.nz
Guest

Posted: Sun Feb 19, 2012 1:14 am Post subject: Removing magnetic plug from Rotax 912 gearbox

Richard,

I had the same problem and got it out with a metal chisel and burred a slot to force it anti clockwise with a hammer. Then replace it with a new type. Put some anti seize compound on the thread.

Cheers,

Tim



Tim Ward

12 Waiwetu Street

Fendalton,

Christchurch,  8052

New Zealand.



ward.t(at)xtra.co.nz



Ph 64 3 3515166

Mob 0210640221

On 19/02/2012, at 9:49 PM, "Richard Lamprey" <lamprey.richard(at)gmail.com> wrote:



 	  Quote: 	
		   

 

 Does anyone know the best way to get this plug out?  I burred the hexagonal inset, so hex key (allen key) no longer going to get it out.  I have tried clonking gently with hammer (as per various instructions) to loosen, to no avail.

 

 My plug replacement is of the new variety that can be removed with a ring-spanner.  Just got to get the old out and check for filings.

 

 Perhaps a left handed thread bolt/screw that self-taps into the burred inset??

 

 Any ideas welcome.

 Richard

 Europa 168, Kenya

 

 

 

 

 Read this topic online here:

 

 http://forums.matronics.com/viewtopic.php?p=366581#366581

craigb(at)onthenet.com.au
Guest

Posted: Sun Feb 19, 2012 2:09 am Post subject: Removing magnetic plug from Rotax 912 gearbox

You could use an Eazy_out. It requires you to drill a hole, Although, the

correct size easy_out may fit into the hole

Left from the allen key hole. You can normally buy a set of them for about

$20. Its like a left handed really coarse

Thread high tensile screw. Good quality easy-outs are tool steel, so they

will cut into the hole, to give a really

Good grip on the remnants of the bolt



Good luck



craig

kevinmarie(at)blueyonder.
Guest

Posted: Sun Feb 19, 2012 2:19 am Post subject: Removing magnetic plug from Rotax 912 gearbox

I wouldn't use an easy out as the magnetic bit could fall off when you drill for the easy out. A chisel and hammer to knock the plug round worked for mine.



Kevin

On 19 Feb 2012, at 10:08, "craig" <craigb(at)onthenet.com.au> wrote:



 	  Quote: 	
		   

 

 You could use an Eazy_out. It requires you to drill a hole, Although, the

 correct size easy_out may fit into the hole

 Left from the allen key hole. You can normally buy a set of them for about

 $20. Its like a left handed really coarse

 Thread high tensile screw. Good quality easy-outs are tool steel, so they

 will cut into the hole, to give a really

 Good grip on the remnants of the bolt

 

 Good luck

 

 craig

stabelvej9(at)gmail.com
Guest

Posted: Sun Feb 19, 2012 2:34 am Post subject: Removing magnetic plug from Rotax 912 gearbox

Mine too ...  

Gert

Den 19/02/2012 kl. 11.18 skrev Kevin Challis:



 	  Quote: 	
		   

 

 I wouldn't use an easy out as the magnetic bit could fall off when you drill for the easy out. A chisel and hammer to knock the plug round worked for mine.

 

 Kevin

 

 

 On 19 Feb 2012, at 10:08, "craig" <craigb(at)onthenet.com.au> wrote:

 

> 

> 

> You could use an Eazy_out. It requires you to drill a hole, Although, the

> correct size easy_out may fit into the hole

> Left from the allen key hole. You can normally buy a set of them for about

> $20. Its like a left handed really coarse

> Thread high tensile screw. Good quality easy-outs are tool steel, so they

> will cut into the hole, to give a really

> Good grip on the remnants of the bolt

> 

> Good luck

> 

> craig

> 

> 

> 

> 

>

Ivor Phillips

Joined: 16 Jan 2006
Posts: 253
Location: London UK

Posted: Sun Feb 19, 2012 8:06 am Post subject: Removing magnetic plug from Rotax 912 gearbox

Before using the chisel method us some localised heat from a needle jet butane gun, then a few sharp taps will see it out,

 best wishes

 ivor

 2012/2/19 Gert Dalgaard S�rensen <stabelvej9(at)gmail.com (stabelvej9(at)gmail.com)>

 [quote]--> Europa-List message posted by: =?iso-8859-1?Q?Gert_Dalgaard_S=F8rensen?= <stabelvej9(at)gmail.com (stabelvej9(at)gmail.com)>

 

Mine too ... �

Gert

Den 19/02/2012 kl. 11.18 skrev Kevin Challis:

  

 	  Quote: 	
		   --> Europa-List message posted by: Kevin Challis <kevinmarie(at)blueyonder.co.uk (kevinmarie(at)blueyonder.co.uk)>



 I wouldn't use an easy out as the magnetic bit could fall off when you drill for the easy out. A chisel and hammer to knock the plug round worked for mine.

 >
	


 	  Quote: 	
		   Kevin

 On 19 Feb 2012, at 10:08, "craig" <craigb(at)onthenet.com.au (craigb(at)onthenet.com.au)> wrote:



> --> Europa-List message posted by: "craig" <craigb(at)onthenet.com.au (craigb(at)onthenet.com.au)>

 >>
	


 	  Quote: 	
		  > You could use an Eazy_out. It requires you to drill a hole, Although, the

> correct size easy_out may fit into the hole

> Left from the allen key hole. You can normally buy a set of them for about

 >> $20. Its like a left handed really coarse
	


 	  Quote: 	
		  > Thread high tensile screw. Good quality easy-outs are tool steel, so they

> will cut into the hole, to give a really

> Good grip on the remnants of the bolt

 >>
	


 	  Quote: 	
		  > Good luck

>

> craig

>



&g====================
	


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[b]

ptag.dev(at)tiscali.co.uk
Guest

Posted: Sun Feb 19, 2012 1:17 pm Post subject: Removing magnetic plug from Rotax 912 gearbox

Hi! A heat gun (hot air only) worked for me then a good clout with a hammer

and a chisel on the outer diameter.

Regards

Bob Harrison.



--

kingsnjan(at)westnet.com.
Guest

Posted: Sun Feb 19, 2012 3:23 pm Post subject: Removing magnetic plug from Rotax 912 gearbox

Gentlemen,



When removing the magnetic plug, in addition to the heating, cooling and impacting methods, it is important to use the correct tool. 



Early engines had a 6 mm Allen fitting.  Later engines have a #40 Torx fitting requiring a #40 Torx socket. The latest engines of course now have the Hex headed plug.



Look carefully because the Torx fitting looks very much like an Allen key one at first sight.



Also, don't use a cheap Torx socket, a Snap-on one may prove to be cheap in the long run!



Cheers

Kingsley from Oz - Enjoying my first real cross country trip in a 914 Mono. 800nm from home at the moment but still in the same State!  Truly is a great cross country aircraft. 



Sent from my iPhone



On 20/02/2012, at 7:16 AM, Bob Harrison <ptag.dev(at)tiscali.co.uk> wrote:



[quote] 

 

 Hi! A heat gun (hot air only) worked for me then a good clout with a hammer

 and a chisel on the outer diameter.

 Regards

 Bob Harrison.

 

 --

rlborger(at)mac.com
Guest

Posted: Sun Feb 19, 2012 6:08 pm Post subject: Removing magnetic plug from Rotax 912 gearbox

Fellow Europaphiles,



Yes, heat gun, impact device or impact wrench and proper drive.  I used a heat gun, #40 Torx and impact device (all from Sears) to remove the magnetic plug from my engine the first time.  The impact device was a strange black thing with a square 3/8" drive on one end and the other end was round to hammer upon.  Heated the block around the plug with the heat gun, put the Torx drive on the impact device, made sure it was properly and firmly seated in the plug and then whacked it a good one with a 2 lb hammer.  The impact simultaneously applied both an inward force and a loosening torque force.  Took several good whacks (take care not to crack the block) to get it loose enough to remove with a ratchet.  I have since acquired a nice little Makita cordless impact wrench that I would use for the plug removal should it be necessary.  Hopefully, by using anti-sieze and proper torque upon last reinstallation, it will not be necessary later this week when I begin the annual condition inspection.



If you have buggered up the hole in the plug such that your Torx or hex wrench will no longer work, Sears has a set of removal tools with a strong left-hand bite that do not require one to drill out the hole.  They could possibly be used to remove the plug.  I have used them to remove other messed up screws that I though would be impossible to get out.



I can provide pictures of these tools should you want to see what they actually look like before you go searching for them.



Blue skies & tailwinds,

Bob Borger

Europa XS Tri, Rotax 914, Airmaster C/S Prop.

Little Toot Sport Biplane, Lycoming Thunderbolt AEIO-320 EXP

3705 Lynchburg Dr.

Corinth, TX  76208-5331

Cel: 817-992-1117

rlborger(at)mac.com



On Feb 19, 2012, at 5:21 PM, Kingsley Hurst wrote:



 	  Quote: 	
		   

 

 Gentlemen,

 

 When removing the magnetic plug, in addition to the heating, cooling and impacting methods, it is important to use the correct tool. 

 

 Early engines had a 6 mm Allen fitting.  Later engines have a #40 Torx fitting requiring a #40 Torx socket. The latest engines of course now have the Hex headed plug.

 

 Look carefully because the Torx fitting looks very much like an Allen key one at first sight.

 

 Also, don't use a cheap Torx socket, a Snap-on one may prove to be cheap in the long run!

 

 Cheers

 Kingsley from Oz - Enjoying my first real cross country trip in a 914 Mono. 800nm from home at the moment but still in the same State!  Truly is a great cross country aircraft.

tennant

Joined: 19 Apr 2011
Posts: 121

Posted: Mon Feb 20, 2012 12:34 am Post subject: Re: Removing magnetic plug from Rotax 912 gearbox

And there was me thinking that I was the only dumbo to round off my plug.

I think they made the first batch from chewing gum they are so soft!



Barry

_________________
Barry Tennant
D-EHBT
At EDLM - Germany

Remi Guerner

Joined: 14 Dec 2010
Posts: 284

Posted: Mon Feb 20, 2012 11:27 am Post subject: Re: Removing magnetic plug from Rotax 912 gearbox

After I wrecked the torks hole, I cut two flats using a hand saw blade. Then I was able to use a regular wrench to remove the magnetic plug. I bought a good quality torks wrench for use with the new plug and never had the problem ever since.

Regards

Remi Guerner

Richard Lamprey

Joined: 15 Jul 2011
Posts: 95
Location: Kenya

Posted: Mon Feb 20, 2012 9:14 pm Post subject: Re: Removing magnetic plug from Rotax 912 gearbox

Many thanks to all for your comments.  Lots of ideas, I'll try with the least brutal and work upwards.



All best

Richard

Richard Lamprey

Joined: 15 Jul 2011
Posts: 95
Location: Kenya

Posted: Mon Dec 31, 2012 11:16 pm Post subject: Removing magnetic plug Rotax 912 gearbox, Bob, Sears tool?

Happy New Year to all, and apologies for returning to an old topic...



Bob (Borger) had an option for a Sears tool that would remove the plug.  Bob, do you have details of that (picture, part number?).



Best

Richard

Kenya

rlborger(at)mac.com
Guest

Posted: Tue Jan 01, 2013 6:12 am Post subject: Removing magnetic plug from Rotax 912 gearbox

Richard,



Yes, I have a Sears tool that works.  I'll get the necessary information and a picture the next time I'm at the hanger.  Maybe later today.  



Weather has been awful for flying for the last several days, but lovely considering the draught conditions we've had.  I'll not complain about cool, rainy, foggy weather in North Texas.



Blue skies & tailwinds,

Bob Borger

Europa XS Tri, Rotax 914, Airmaster C/S Prop.

Little Toot Sport Biplane, Lycoming Thunderbolt AEIO-320 EXP

3705 Lynchburg Dr.

Corinth, TX  76208-5331

Cel: 817-992-1117

rlborger(at)mac.com



On Jan 1, 2013, at 1:16 AM, Richard Lamprey <lamprey.richard(at)gmail.com> wrote:






Happy New Year to all, and apologies for returning to an old topic...



Bob (Borger) had an option for a Sears tool that would remove the plug.  Bob, do you have details of that (picture, part number?).



Best

Richard

Kenya

rlborger(at)mac.com
Guest

Posted: Tue Jan 01, 2013 11:14 am Post subject: Removing magnetic plug from Rotax 912 gearbox

Friends,

This is the hand tool that can be used to remove the magnetic plug.

[img]cid:721F83DA-E04F-470D-894C-F1AA6BAA1BAC[/img]

It requires a 1/2" drive #40 Torx bit.



For specific instructions on removal of the magnetic plug see the instruction video at Rotax-Owner.com.  They provide a quite detailed tutorial.



Blue skies & tailwinds,

Bob Borger

Europa XS Tri, Rotax 914, Airmaster C/S Prop.

Little Toot Sport Biplane, Lycoming Thunderbolt AEIO-320 EXP

3705 Lynchburg Dr.

Corinth, TX  76208-5331

Cel: 817-992-1117

rlborger(at)mac.com (rlborger(at)mac.com)



On Jan 1, 2013, at 8:11 AM, Robert Borger <rlborger(at)mac.com (rlborger(at)mac.com)> wrote:

Richard,



Yes, I have a Sears tool that works.  I'll get the necessary information and a picture the next time I'm at the hanger.  Maybe later today.  



Weather has been awful for flying for the last several days, but lovely considering the draught conditions we've had.  I'll not complain about cool, rainy, foggy weather in North Texas.

On Jan 1, 2013, at 1:16 AM, Richard Lamprey <lamprey.richard(at)gmail.com (lamprey.richard(at)gmail.com)> wrote:



--> Europa-List message posted by: "Richard Lamprey" <lamprey.richard(at)gmail.com (lamprey.richard(at)gmail.com)>



Happy New Year to all, and apologies for returning to an old topic...



Bob (Borger) had an option for a Sears tool that would remove the plug.  Bob, do you have details of that (picture, part number?).



Best

Richard

Kenya

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ward.t(at)xtra.co.nz
Guest

Posted: Tue Jan 01, 2013 11:51 am Post subject: Removing magnetic plug from Rotax 912 gearbox

Richard,

Rotax brought out a replacement plug with a  hexagonal connection shape (bolt) which is good.



Tim



Tim Ward

12 Waiwetu Street

Fendalton,

Christchurch,  8052

New Zealand.



ward.t(at)xtra.co.nz



Ph 64 3 3515166

Mob 0210640221

On 1/01/2013, at 8:16 PM, "Richard Lamprey" <lamprey.richard(at)gmail.com> wrote:



 	  Quote: 	
		   

 

 Happy New Year to all, and apologies for returning to an old topic...

 

 Bob (Borger) had an option for a Sears tool that would remove the plug.  Bob, do you have details of that (picture, part number?).

 

 Best

 Richard

 Kenya

 

 

 

 

 Read this topic online here:

 

 http://forums.matronics.com/viewtopic.php?p=391314#391314

Richard Lamprey

Joined: 15 Jul 2011
Posts: 95
Location: Kenya

Posted: Wed Jan 02, 2013 3:34 am Post subject: Re: Removing magnetic plug from Rotax 912 gearbox

Thanks Bob, this may do the trick.  I'll order one.  Challenge I have is to get it to East Africa, but thats another story....



Tim, thanks, I have the new one, just need to get the old one out.



All best

Richard

h&jeuropa

Joined: 07 Nov 2006
Posts: 649

Posted: Wed Jan 02, 2013 4:41 am Post subject: Re: Removing magnetic plug from Rotax 912 gearbox

Richard,



The impact tool that Bob used has been copied by the Chinese and is available at motorcycle shops and the like.  You may be able to find it locally.  The Chinese tool isn't high quality but you only need it to work once!



Jim & Heather

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