I have a 2005, non S, Manual trans.

Went to change the fluid, but the Fill plug is so snug can not get it loose.

Any Ideas

AMen

 

Consider using an oil extraction pump. They can be found for $40-$60 at local marine supply stores or used in Craigslist. When the lower plug is in too tight the risk is rounding off the head or stripping the threads because there is a tight bond between the dissimilar pan metal and plug metal. Don't ask me how I know.

 

Not really an option on the trans.

If the fill plug is in too tight first make sure you have the correct allen head inserted all of the way.
Then go to work with a longer handle.
Not many other options.
If you strip the hole you are still in the same boat of having to take it to someone.

Sounds like you have followed the JUST DON"T TAKE THE DRAIN PLUG OUT FIRST rule.
It is a rule to live by.

 

What were you using? I found that MINI really makes these plugs tight at the factory. I couldn't get the ones on my S loose the first couple of times that I tried. You need a tool with lots of leverage, like an 18" breaker bar and the proper adapter for your plug.

 

Mine was rather tight as well on my 6 speed. I put my 1/2" ratchet on it with the allen socket and hit the ratchet with the palm of my hand a few times and it came free. You just need to give it a nice whack to break the torque.

 

They are in there snug. Just make double-sure you're using the correct size allen and then get a longer lever