Rookie mistake. Stripped Final Drive drain plug.

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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby Adventurer » Mon Mar 19, 2012 2:06 pm

"No Guts No Glory", the saga continues.

To recap briefly, Adventurer had made the decision to go forward. Throwing caution to the wind and disregarding sound medical advice from mental health specialist not to undertake such project, less the likelihood of forever being medicated and diapered along with unknown years of therapy sessions, proceeds anyway to conduct maintenance of his beloved (only had it 14 months) '04 BMW GS. The very early procedures went well, removal of gas tank and filter replacement (though tank not re-installed) and replacement of air filter, drain and replacement of transmission fluid! Ah....life is good. Then, with ABSOLUTELY no help or guidance from anyone, all by himself no less, he manages to to strip the final drive drain plug during re-installing to a condition of uselessness not seen in these parts for years, leaving seasoned techies in awe!

In the last exciting episode, Adventurer had managed successfully to waste time drilling, prying and cutting the above mentioned plug in attempt to save himself from the inevitable task of removing the final drive. To no one's surprise none of these attempts showed positive results.

With great (mal)adroitness and the Bernoulli aerodynamics of a flying manhole cover, Adventurer now basks in the glory of fondling his final drive.

Today we find Adventurer taking up the task of removing the final drive in full mechanics mode...FULL STEAM AHEAD! What's that you say? You don't have a 30mm socket, 12mm allen wrench, nor a heat gun in your bicycle tool box? Say it ain't so!! Alas, all is not lost. To the nearby service station where you are only seen getting air for your Lance Armstrong bicycle, while decked out in spandex and leaving the employees wondering about your sexual gender/orientation. With coffee in hand for everyone, the aforementioned tools are willingly loaned. The chuckling heard as Adventurer was leaving did not go unnoticed. Not to be deterred we march forward.

Success!! In a procedure (if done by Jim VonBaden would have been completed before the full head of a poured pint of Guinness had settled) which could only be timed with a calender, the final drive is successfully removed.

To be continued........
Attachments
Final Drive out 007.JPG
Final Drive out 009.JPG
Final Drive out 003.JPG
Final drive out.
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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby adooley » Mon Mar 19, 2012 4:13 pm

Bravo! Bravo! =D> =D>

You just might make the Special Olympics after all!! (just kidding)

In all seriousness, you are doing an amazing job for first-timer and your preseverance is becoming legendary (you reaching the ranks of a Jim or Chaz). Thanks for keeping us informed of your progress and way to hang in there!

On a side note, would you like to write this adventure up and submit it for publication in the BTS?
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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby JimVonBaden » Mon Mar 19, 2012 6:01 pm

Hey, if nothing else this is a fgun read! :oops:

Wes, good fodder for the BTS! :D

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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby Adventurer » Mon Mar 19, 2012 6:18 pm

Final drive out! Now what?

First thing, get the tools back. It's a brave man who flirts with the possibility of an unscheduled visit to ER for failure to return tools in a timely manner (truth be known two local hardware stores were visited prior to the service station, neither carried a 30mm socket or 12 mm allen, Lowe's/Home Depot are 25 miles away....these tools will not be asked for again.)

Prior to returning the tools I made it a point to remove my sterilized blue latex gloves, then methodically massage my hands with grease. Making sure to work just enough around the nail cuticles of each hand so as to be noticed. Trash an old t-shirt with some and off we go, but not before looking up online the most current garage/mechanic jokes.

Now we get serious.

Final drive in tow, I present it to Mick the Mechanic. Mick seems to know his stuff, long time garage monkey. I explain and show him the issue with the Final Drive plug. So far so good. I should mentioned I recently obtained the Clymer manual pertaining to the '04 GS, although somewhat foreign to me, I'm sure it will of great help to Mick. Within it's pages is a detailed schematic of the Find Drive unit.

As a form of confirmation, the questioned is (Mick not BMW motorcycle savoy, but a competent mechanic none the less) this: Mick is assuming he can remover the inside cover of the Final Drive accessing the interior of the housing, thus locating the damaged plug, then drill it and re-tap. With schematic in hand and following due mechanic diligence is there anything specific he should be made aware on this repair? To those of you familiar with this procedure it seems straight forward following SOP. However I like to run it by the room for any additional input.
Attachments
Final drive flange cover 003.JPG
"The Patient"
Final drive flange cover 002.JPG
Final drive flange cover 001.JPG
Inside cover.
Richard
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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby JimVonBaden » Mon Mar 19, 2012 6:52 pm

If you are determined to pull it apart, make sure you pay close attention the the shimming, and get a new seal.

IMHO you should also have the BUA number on your speed dial!

http://beemersuberalles.com/

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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby Adventurer » Mon Mar 19, 2012 7:11 pm

I'm NOT determined to take it apart. The mechanic's concern is that if he were to drill it out as is, he MAY be introducing foreign substances into the housing and thus further damage.

If this is NOT a serious concern and can be addressed without taking it apart (some type of flushing etc.) ...'I'M ALL FOR THAT! Believe me.
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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby guitardad » Mon Mar 19, 2012 9:06 pm

Hey, anybody willing to post up pics like these is Ok by me! :)

I have to agree with Mick - if you're going to have to machine the housing (and I think you are) to get the plug out, best to make sure not to get any debris into the gears. Replacing the seal while it's apart is a very good idea. I've never taken a FD apart, but I know there are some interference-fit parts in there. He'll need to heat some things to get them apart. As long as that's in the manual, he should go ahead.

Let us know what he finds with the drain plug threads. I'm guessing the aluminum hosing threads are now tightly seized to the steel drain plug. But I'd like to know for sure.
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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby Adventurer » Mon Mar 19, 2012 9:51 pm

OK...

Being the devil's advocate a new twist. Assuming this is correct: the tip of this drain plug is magnetized.

My question is if the drill/re-tap were to be done as is (without taking the Final Drive apart) and a series of timely Final Drive fluid drains were to take place, thus gathering any foreign substances on the tip, would this eliminate the possibility of any future damage from occurring to the Final Drive?
Actually how much shavings are actually going to be introduced to the housing as is?

Additionally, can some type of magnetized probe (for lack of a better way of saying it), be introduced into the housing after the re-tap to gathering any shavings?
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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby guitardad » Tue Mar 20, 2012 7:35 am

The problem is, the housing is aluminum. So any shavings from drilling it out will not be attracted to the magnet.
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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby Georgeinva » Tue Mar 20, 2012 8:50 am

It is best to pull it apart. If you don't want to the best way to prevent any chips from entering the final drive is to work from the bottom. If you drill and tap from under the hole the chips will away from the final drive. This alone will not be enough, you should also run a fluid through the final drive during the drilling and taping. I know that is asking a lot for DIY but a machine shop should be able to do it.
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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby Adventurer » Tue Mar 20, 2012 9:02 am

Chaz I somewhat missed the aluminum issue, got it.

A professional machine shop will be looked into today, along with running the schematic of the Final Drive by Mick and finding his comfort zone. It's early in the day and the lap top will be taken on the road so I can check here for latest (hopefully) painless/doable suggestions or options.

Thank you all for input on this, it is greatly appreciated.
Richard
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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby Adventurer » Tue Mar 20, 2012 10:07 am

9:45 a.m. update.

Few phone calls were made regarding the Final Drive (yes I know, sometime I capitalize it sometimes I don't, duh..go figure)

Not surprisingly, this forum room was given high "kudos" of it's in-dept and thoughtful responses to this issue from non BMWBMW sources. With one source responding something to the effect, " sounds like you got the A team all over this!"

It's as obvious as June bugs splattered over your face shield dancing along the "Dragon Tail", there are but two worthy options, both with there own caveat.

A. Leave as it, having it properly drilled with fluid introduced during the process, thus eliminating or significantly lessening the introduction of shavings into the housing.

B. Take apart. Thus truly eliminating the shavings issue though presenting potentially other issues/problems/cost, such a Jim pointed out, the least of which being the shim and god knows what else.

Hitting the road soon with Plan A as the option to be selected.

Let's see what the day brings.
Richard
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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby Adventurer » Tue Mar 20, 2012 5:56 pm

Final Drive admitted....surgery schedule for 10: a.m. tomorrow morning.

It's true. After taking the Final Drive to a small local BMW Hospital and consulting with staff, it was determined that the best course of action was to "open her up"
The staff indicated that I did the right thing by bringing her into them, as a second (not as serious) condition was discovered ( leaking seal) that may have been missed if this were to be perform elsewhere. I will be allowed to watch the surgery if I so desire.

Returning to my beloved GS and to take my mind off the upcoming operation, I decided to now tend to the oil/filter change and valves along with new spark plugs that were on the agenda.

Re-installed the gas tank, added some fresh gas, up to temp., turn off and remove filter and drain oil. No leaks initially noticed on as tank, then I didn't put much in.

While oil is draining, let's get serious and dive into the valves. I'll start on the left side.................



"HOUSTON WE HAVE A PROBLEM..."

Removing the left side coil stick (see, I'm learning this stuff) I get a funny feeling. I didn't have to be a Master BMW Tech to know that this should not have come out in TWO PIECES! AHHA! The recent poor performance I thought I was experiencing was not in my head nor a bad tank of gas.
I'm finding $ 125.00 replacement new for two, wow....any better prices?


Stick coil 002.JPG
Broken coil stick.


Stick coil 001.JPG
Same coil.


A little research and I come across this: http://www.bmwmoa.org/forum/showthread.php?t=27851

I can't make this stuff up folks............"And the hits just keep on coming"

Everyone feel to jump in.
Richard
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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby Adventurer » Wed Mar 21, 2012 8:28 am

After cleaning my glasses, I'm finding these coil sticks at $ 125. EACH!!
Richard
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Re: Rookie mistake. Stripped Final Drive drain plug.

Postby radon222 » Wed Mar 21, 2012 9:46 am

Well you do realize that BMW stands for "Bring More Wampum" :shock:
'14 GSAW <--mine
'12 R1200RT <-- The Wifey's pimpin ride
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