Filler plug rear differential

[JimShoe]

Read the threads on removing the filler plug on the rear differential. I cleaned, heated treated with PB bLaster for a few days. Bought impact extensions from Harbor Freight and I used a impact and then a breaker bar. I ended up stripping the inside. Not sure what I can do next.

 

[The_Roadie]

Get a nut or bolt welded to it and use an impact tool to break it free.

Or give up as I just did and have an O2 sensor bung welded at the right height into my cover, and close it up with a bolt. Easier to fill that way.

 

[tblazerdude]

if you already drained it your going to have to fill it through the vent hose. It's gonna take forever. You need to drill out that bolt, or make a new hole, thread it, and put a bolt with a nylon washer to seal it. Getting that bolt out is the best option, but as roadie said, you will need something welded to it, or just make a new fill hole.

 

[gmcman]

I used one of these suction guns from NAPA then attached a smaller hose to the end that matches the vent nipple. Pull the vent hose from the axle housing and should take about 4 refills from the gun.

 

[cartman57]

Read the threads on removing the filler plug on the rear differential. I cleaned, heated treated with PB bLaster for a few days. Bought impact extensions from Harbor Freight and I used a impact and then a breaker bar. I ended up stripping the inside. Not sure what I can do next.

Could try to get something like these locally Nipple Extractor from BrassCraft | The Home Depot - Model T167

http://www.mcmaster.com/#screw-extractors/=jepng6

They work well.

 

[JimShoe]

I haven't drained the oil, so TB is still good to drive. I think first I'll try the weld a bolt to the plug and if that doesn't work I'll go with the fill hole on the back cover. Thanks, I had run out of good ideas and appreciate yours.

 

[The_Roadie]

Yah, I hate to admit messing up my plug so badly, but I tried those exact nipple extractors, and they chewed up the recess and then started spinning. Then I got uncharacteristically angry and went to town with an air chisel and started doing damage to the aluminum housing. Then I quit.

 

[JimShoe]

The air chisel sounds familiar. I think I was in the same place as you. I'm leaning toward the filler hole on the back cover, seems like the best plan (clever). Thanks.

 

[Fire06]

Maybe once you get something welded to it you could put some heat to it and then hit it a few time to break loose the treads. I have used it a few times to get that @#$% bolt/nut that will not move and it has worked. Good luck

 

[Guano]

My fillplug was stripped by way of tightening...At The Factory!!!
Oxygen Acetylene torch is the only way to heat something out. I bought mine when I was 18 a sizable investment at the time but for me, worth every penny.