Rear Diff Fill Plug Stripped

[snowmirage]

What an unbelievable headache....

Went to change the fluid in the rear diff and in a moment of stupidity I drained the fluid before I made sure I could get the fill plug out......



Ya not smart.

I've tried various penetraters, a few different 3/8" extensions trying to find out that was a better fit, even took a torch to the housing surrounding the plug for a good 20 min or so it seemed and still cant get that thing to budge.

The last attempt as I was tweaking on the thing with all my might it slipt and stripped the square hole the 3/8" extension goes into.

I'm running out of ideas. Anyone have any advice?

I dont have access to a welder (nor have I really ever used one), but thought it might be possible to weld a bolt to it and use that to turn it out.

Short of that I'm out of ideas I think.

Unless I can buy an aftermarket diff cover for the rear that has a fill plug in it? But in all my browsing of the forums I dont think I have ever heard one mentioned so I'm not to sure if anyone makes one.

[bartonmd]

I've use a 3/8" square EZ-out before, with some success (thought I cut it shorter to get a bigger size and tighter fit)... When that got all messed up, I took it to a buddy's house (before I had a welder) and welded a 3/8" extension to it, and used an impact on that extension to get it out, then replaced it with a brass plug...

Being that you don't have access to a welder, just get a cheap 3/8M - 1/2F adaptor and head to your nearest local welding shop... I think mine (where I worked in HS) has like a $15 minimum charge for less than 15 minute jobs... It's like a 5 minute job, so it will likely cost you less than $20... Just have them weld the adaptor onto the plug, then take it home and hit it with an impact...

Mike

[fishsticks]

Fill it via the vent tube. It'll be slow going but will work.

[bartonmd]

Fill it via the vent tube. It'll be slow going but will work.

That's a trail or last-minute (or "I'm about to sell this") fix, really...IMO, just fix it right...

Mike

[fishsticks]

Fill it via the vent tube. It'll be slow going but will work.

That's a trail or last-minute (or "I'm about to sell this") fix, really...IMO, just fix it right...

Mike

He already drained the fluid. He needs to get it somewhere to fix it.

[snowmirage]

Thanks for the tips, that's pretty much the road I'm going to have to take I think.

How concerned should I be about moving this with almost zero fluid in the rear diff? (just what ever stuck to the gears after I drained it)

I may have a friend a few football fields down the road with a welder, or worst case I have it put on the back of a truck and towed some place.

but I really don't want to damage anything.

[bartonmd]

That's a trail or last-minute (or "I'm about to sell this") fix, really...IMO, just fix it right...

Mike

He already drained the fluid. He needs to get it somewhere to fix it.

Oh, I didn't catch that...

Slow, idling down the road 200 yards with no fluid is fine... I wouldn't go a mile, though...

Mike

[Trail X]

Best case, remove the rear driveshaft and put it in 4WD, so you're powered by only the front wheels. The gear oil really protects most against the rubbing between the gear teeth.

[Trail X]

Oh, and...

http://www.yourcovers.com/diffcover_11035.php

[navigator]

maybe you can source one at a junk yard real quick.
too bad there isn't a drain plug or you could fill via the drain slowly.
I'm with Kyle, try filling via the drain and get it somewhere to get the plug out.

[Gordinho80]

I'm with Kyle, try filling via the drain and get it somewhere to get the plug out.

I think you meant Donny... and filling via the vent tube.

[OregTrailBlazin]

Do the plastic bag trail trick.... Put the oil in a cheap, thin ziplock and stuff it inside, bolt the cover back in place and drive to your buddies house..

[fishsticks]

Do the plastic bag trail trick.... Put the oil in a cheap, thin ziplock and stuff it inside, bolt the cover back in place and drive to your buddies house..

That's how I got oil back in my old G80 after exploding it... totally forgot about that trick!

[bartonmd]

That was actually my first thought to get it to someplace with a welder, but I'd be afraid of the bag getting hung up in the feed for a bearing, and starving it for oil... Maybe unlikely, and I'd do it as a trail fix, but not otherwise, if I had a choice...

Mike

[bdp1978]

Small chisel and a hammer, use the chisel to catch an edge on the stripped area inside the plug, line it up and give it a good smack- counterclockwise obviously. This trick works more than you could imagine to break threads loose when something is already fubared.

[navigator]

I'm with Kyle, try filling via the drain and get it somewhere to get the plug out.

I think you meant Donny... and filling via the vent tube.

you're right, sorry about that. I'm sure he's been called worse!

[dvanbramer88]

either fill it through the breather or do the bag trick to get it to the welder.

[The Roadie]

If you don't want to worry about the bag, you can freeze the oil in little chunks using dry ice.

[OregTrailBlazin]

you can freeze the oil in little chunks using dry ice.

I've never seen this trick, any resources?

[chevycrew]

How about taking the cover to a shop and having a fill plug installed in the cover?

Permanent solution...