TF80SC fill plug wanted
 

My TF80SC fill plug for Volvo XC90 D5 2010 is getting hard to open due to wearing off and slips at last fluid change and have to repeat a couple of times in next few weeks.

So want to buy TF80SC fill plug before next fluid change.

Any advice on availability or from where I can buy one?

Main dealer.

Thanks cheshird5.

Was going to ring an Indy specialist in Stockport / dealer in Bury tomorrow morning. As it was too late to ring them, posted to seek advice for alternate options.

Any advice on opening the fill plug ( torx 55 ) if it continues to slip with torx bit?

Thanks in advance.

Use a larger torx or experiment with different hex/Allen heads.
That bolt really doesn't need doing up so tight that it rounds so be a little more gentle especially with the replacement.

there is a main dealer in stockport if thats any nearer than bury.:regular_smile:

Thanks Simmy,

That is certainly nearer from south Manchester.
Searched and found half the distance as compared to Hatfields in bury.

I'll certainly try them for the next part as have already ordered this one from Hatfields in Bury, collecting Monday afternoon / Tuesday morning.

Any suggestions to open the almost completely rounded fill plug ( torx 55) please before I go to local garage for help with it on Friday probably!

try a straight screwdriver taped gently in . this plug should not be overley tight .check the drain and level plugs they might also be damaged dont forget new sealing washers. good luck let us know how you progress:regular_smile:

Thanks again for the advice.

Here is summary of the ordeal.

Tried torx 55 and then hex but failed to open fill plug, rather made the things worst by rounding even more by cutting the edges which are there for torx bit.

Tried 'bolt extractor' https://www.toolstation.com/shop/p51010 from tool station. As advised drilled pilot hole and then used one of these bolt extractors. Again failed as it started spinning free. Later I realised that it might be a mistake to use drill with this as the drill speed spoiled the idea of opening the actual bolt perhaps. Or this 'bilt extractor' thing might not be suitable for the fill plug made of aluminium.

Made a cut with circular saw on the top of fill plug and tried with big flat object ( flat screw driver was not wide enough). Again no success.

Even tried the superglue and spray combination to harden the flat object grip in the cut / slot but again without success.

Tried with the chisel and flat head screwdriver by tapping with hammer but no success.

Used the flame to heat up fill plug head to a reasonable level and then tapped with the flat screwdriver and hammer -- it worked!

After tapping for half dozen times or so, the fill plug started moving. It was merely half of a quarter turn or even less and then I was able to open it with hand.

Here is what that I think worked!

The fill plug was tightened more than enough which is a mistake or what I read about 40 Nm to tighten the fill plug is incorrect as I later read somewhere else that it is 30 Nm. Hand tightening or just a little gentle tightening with torx bit is more than sufficient I believe as you guys have already suggested and I experienced!

Heating up of the fill plug head made the rubber ring reasonably soft and then tapping with flat head screw driver and hammer did the trick.

Lesson learned!!!