Front diff fill bolt

[97audia4]

Anyone else have an issue getting the fill plug out of the front diff.

I am making a long trip the up coming weekend towing a trailer and I wanted to change out the fluid. The fill bolt was so tight I snapped a breaker bar and started twisting the bolt.

Any tips from people in the same situation ?

 

[Eod1]

Have u ever had it out before?. If not the factory over tighten it. A little heat and a little PB blaster or penetrating oil and a new brake bar with extension tube should get it out. Ounce out use just a little anti sneeze lubricant on the threads.

 

[Eod1]

You might need to just get a new cover, gasket and filler bolt that would be the faster way

 

[97audia4]

You might need to just get a new cover, gasket and filler bolt that would be the faster way

Not sure I can change the cover, this is the front diff, Ill try some kroil and heat but I damn near sheared the bolt off of it trying to loosen. Ill order a new fill plug tonight just need to get it off.

 

[swathdiver]

You might need to just get a new cover, gasket and filler bolt that would be the faster way

1500 GMT900 front differential does not have a cover and gasket like the rear. The drain is on the botton, the fill port on the side.

 

[Eod1]

So how do they pull the guts out of it.

 

[Eod1]

Yup I forgot. It's a clam shell. Well then if you really need that fill plug out and you strip it, several ways to get it out. Won't make you happy but it will come out. If you don't want to pull it and put it on the bench and strip it. You can do it in the truck. Last ditch effort drill it in steps. Re tap it and get a new fill plug. Now the bad news. You will have to flush it a lot to make sure you get all metal chips and metal flakes from getting in to the gears and bearings

 

[swathdiver]

Anyone else have an issue getting the fill plug out of the front diff.

I am making a long trip the up coming weekend towing a trailer and I wanted to change out the fluid. The fill bolt was so tight I snapped a breaker bar and started twisting the bolt.

Any tips from people in the same situation ?

It's a pain Jeff, but you could siphon the oil out of the fill port on the side instead and deal with the plug after your trip. I wouldn't be drilling it out or risk cracking the case with a trip coming up. Some knucklehead probably put Loctite on the threads.

 

[Eod1]

It's a pain Jeff, but you could siphon the oil out of the fill port on the side instead and deal with the plug after your trip. I wouldn't be drilling it out or risk cracking the case with a trip coming up. Some knucklehead probably put Loctite on the threads.

Yes he is correct if that trip is like now his way is the fastest. If it in a week or 2 you have time to work on it. It's nothing to stress over

 

[97audia4]

It's a pain Jeff, but you could siphon the oil out of the fill port on the side instead and deal with the plug after your trip. I wouldn't be drilling it out or risk cracking the case with a trip coming up. Some knucklehead probably put Loctite on the threads.

There is another spot to fill at ? Ill just siphon it out of there , didnt see any other spots.

If there is a vent tube I would get some poly line and try it that way, Im just pissed I went under there and ended up not being able to do it because it was so f'n tight. I broke out the 3/4 inch bar and it still wouldnt budge and just starter to tear the bolt head up.

Tried finding my sockets for strips bolts but didnt have time, needed to get moving on the rear diff fluid and transfer case.

 

[swathdiver]

There is another spot to fill at ?

Both plugs are facing the driver's side. The lower one is smaller and in the center. The fill is to your upper left and quite large. There are drawings of them in your owner's manual. For a 2009, it's on page 5-52.

 

[Trailblazzin]

Both plugs are facing the driver's side. The lower one is smaller and in the center. The fill is to your upper left and quite large. There are drawings of them in your owner's manual. For a 2009, it's on page 5-52.

I believe he is asking about another place to fill it because he is having difficulties with the FILL plug and you suggested siphoning out of it. Won’t work if he can’t remove it.

I just changed my front fluids last week and had a heck of a time with the fill plug as well, PB blaster and patience ultimately got it out.


Sent from my iPhone using Tapatalk

 

[swathdiver]

I believe he is asking about another place to fill it because he is having difficulties with the FILL plug and you suggested siphoning out of it. Won’t work if he can’t remove it.

I just changed my front fluids last week and had a heck of a time with the fill plug as well, PB blaster and patience ultimately got it out.

You're right! My reading comprehension skills are not what they once were!

 

[thompsoj22]

allways start with the fill port, if the drain comes out but not the fill you cant service it. since it is only a drain plug it limits the amount of cleaning/flushing you can do anyway. as previously stated, siphon out of the fill plug and forget about it! dont fix it til it breaks as i have been guilty of to many times to count. harbor freight siphon pump $7. oops, if i also misread your post, is it already drained? if so still use a siphon pump and drill out a old wine cork to allow the tube to pass through, install in the drain hole and put the prescribed amount of fluid in. then quickly! pull the cork and install the plug. i know it is a mess but you wont lose more than an ounce or two of fluid.

 

[97audia4]

allways start with the fill port, if the drain comes out but not the fill you cant service it. since it is only a drain plug it limits the amount of cleaning/flushing you can do anyway. as previously stated, siphon out of the fill plug and forget about it! dont fix it til it breaks as i have been guilty of to many times to count. harbor freight siphon pump $7. oops, if i also misread your post, is it already drained? if so still use a siphon pump and drill out a old wine cork to allow the tube to pass through, install in the drain hole and put the prescribed amount of fluid in. then quickly! pull the cork and install the plug. i know it is a mess but you wont lose more than an ounce or two of fluid.

It's the fill plug that is the issue not the drain plug

 

[89Suburban]

allways start with the fill port, if the drain comes out but not the fill you cant service it. since it is only a drain plug it limits the amount of cleaning/flushing you can do anyway. as previously stated, siphon out of the fill plug and forget about it! dont fix it til it breaks as i have been guilty of to many times to count. harbor freight siphon pump $7. oops, if i also misread your post, is it already drained? if so still use a siphon pump and drill out a old wine cork to allow the tube to pass through, install in the drain hole and put the prescribed amount of fluid in. then quickly! pull the cork and install the plug. i know it is a mess but you wont lose more than an ounce or two of fluid.

Great tip!

 

[Rick A]

Anyone else have an issue getting the fill plug out of the front diff.

I am making a long trip the up coming weekend towing a trailer and I wanted to change out the fluid. The fill bolt was so tight I snapped a breaker bar and started twisting the bolt.

Any tips from people in the same situation ?

N

 

[Rick A]

Had the same problem with mine. Drove around to get front diff nice and hot, then melted about ten ice cubes on the fill plug, and with a little persistence the plug busted loose. Make sure you use a six point socket or you’ll stip it

 

[97audia4]

You're right! My reading comprehension skills are not what they once were!

I am going to hit it with some PB plaster in the morning, and then right after my drive home tomorrow it should be hot enough to try and pound a socket on and remove. I really want to get this fluid out before I make a 1000 mile trek with a trailer.

 

[97audia4]

Well this was an epic fail the head of the filler just crumbles even with a 17mm socket hammered on. I put kroil on it this morning and drive it to work and then again when I got home. Tapped the case with a soft mallet and then tried using the breaker bar with no luck. Next I tried to use my 3/8 20v dewalt impact and still no go.