Front Differential Fill Plug Removal?

[EddieC]

On a few attempts at removing the plug it seems pretty well stuck.
I have seen pictures of replacement plugs and the head seems to overlap the opening of the case so it seems penetrating fluid probably will not get past the seal under the head to get to the threads.
Is there a means to get it out without screwing it up and never getting it out?

 

[Doubeleive]

On a few attempts at removing the plug it seems pretty well stuck.
I have seen pictures of replacement plugs and the head seems to overlap the opening of the case so it seems penetrating fluid probably will not get past the seal under the head to get to the threads.
Is there a means to get it out without screwing it up and never getting it out?

I believe it is just a 3/8" socket hole, I just did mine a month ago, I put a socket extension on my ratchet, wouldn't break loose so I used a breaker bar over the ratchet and it broke loose just needed a little more leverage

 

[rdezs]

The socket hole is the drain plug. You always want to make sure you can get the fill plug out before draining.... The fill plugs can be difficult.

Yes, the flange of the fill plug overlaps the case with a built-in o-ring of sorts. Pick up a new one before you get started. I always keep one on the shelf. The "bolt head"... Can't remember but I think it's an 18 mm?.... Well the bolt head doesn't protrude much, and actually appears somewhat tapered. A good 6 point box end wrench and a few taps with a hammer often works. A little heat around the plug helps as well, but don't overdo it.

In the event the bolt head gets rounded off, which is not uncommon, a cheap harbor freight socket and a few spot welds with a MIG welder to the bolt head always does the trick. If you don't have access to a welder, any local shop can do it in just a couple minutes for a nominal fee.

I always use anti-seize when putting the new fill plug in. And follow the torque spec, as you don't want to over tighten it.

 

[EddieC]

Thanks guys.
I did try a breaker bar but didn't want to lean on it too hard fearing messing up the case's threads.
The plug has been in there forever.

 

[Doubeleive]

funny thing is I can't blame the last guy (me) that changed the fluid for over tightening it lol

 

[rdezs]

Time to tack weld on an old socket

 

[rdezs]

And select an old socket that's half inch drive

 

[Joseph Garcia]

On a few attempts at removing the plug it seems pretty well stuck.
I have seen pictures of replacement plugs and the head seems to overlap the opening of the case so it seems penetrating fluid probably will not get past the seal under the head to get to the threads.
Is there a means to get it out without screwing it up and never getting it out?

Same thing happened to mine. I wanted to check the fluid level before a trip, and I could not get the plug out, and I did not want to break anything before the trip. 6 months later, the differential failed and had to be replaced.

 

[Charlie207]

What the drain & fill plugs with a hammer to shock the threads. I'd also consider throwing some heat at them, but you don't want to damage that built-in gasket, unless you plan on replacing the fill cap with a new one.

 

[Doubeleive]

What the drain & fill plugs with a hammer to shock the threads. I'd also consider throwing some heat at them, but you don't want to damage that built-in gasket, unless you plan on replacing the fill cap with a new one.

beside throwing heat at it you could go drive it around first and then try to remove it while warm or at least bust it loose, working around a hot engine is no fun.

 

[Geotrash]

The local quick lube shop near me stocks replacement plugs because apparently they have to booger a lot of them to get them out.

 

[donjetman]

heat then an impact.

 

[EddieC]

Wouldn't you know it that when it was in our sometimes mechanic's shop for something else I asked him to take a stab at the plug.
He said he put the socket on it and it came right out, no sweat. No damage so he put the old one back in and now I have a new spare.
I must have loosened it for him, right?

 

[Joseph Garcia]

Wouldn't you know it that when it was in our sometimes mechanic's shop for something else I asked him to take a stab at the plug.
He said he put the socket on it and it came right out, no sweat. No damage so he put the old one back in and now I have a new spare.
I must have loosened it for him, right?

Of course you did.

 

[rdezs]

If it's an all-wheel drive, you warmed up the differential case on the drive over there. That can make a huge difference.

 

[EddieC]

If it's an all-wheel drive, you warmed up the differential case on the drive over there. That can make a huge difference.

It was dropped off the night before and worked on the following afternoon.

 

[EddieC]

I took it out today to change the gear oil and it was pretty tough again.
The threads were clean so I am thinking where the resistance comes in is where the plug (flange) overlaps and makes contact with the case.
If the plug is cranked down tight there must be quite a bit of friction where the plug flange contacts the case.

By contrast, the drain plug popped right out and it is separated from the case by what looks to be a plastic washer so that type of metal to metal contact doesn't occur there.

I'm glad I changed it. Although there was very little debris on the drain magnet but the oil was gray color.