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rear diff filler plug


 
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colineddy
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Joined: 30 Apr 2008
Posts: 103
Location: Bucks

PostPosted: Wed Oct 11, 2023 12:56    Post subject: rear diff filler plug Reply with quote

Hi,

Cannot for the life of me get the rear diff filler plugs off.

I think they are not mde of metal I  think they were made of some kind of mush.

Heating, sockets, cold chisel to the side etc... nothing. The metal is so fot the cold chisel just takes chunks out of it.

I am considering trying to weld a large but onto the top of it - but that would be tricky so do upside down on the drain plug....

Anyone with similar experience found the right method?

Cheers
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modvrs
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Joined: 03 Oct 2013
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PostPosted: Wed Oct 11, 2023 14:59    Post subject: Reply with quote

Yes, they're not a great design. I use a six sided impact socket on mine and manage to shift them; I've read where people have ground the end of a socket by a few mm to get rid of the bevel and therefore allow greater contact with the nut which doesn't have a very deep head. Welding another nut on worked a treat for me on the front diff fill plug which is an even more stupid design with a 10mm hex on it, the heat from the mig welding helps loosen things up too. Drilling it out is another option. Good luck with it.
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colineddy
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PostPosted: Wed Oct 11, 2023 15:18    Post subject: Reply with quote

Really like the idea of griding down the sides of an impact socket to get it in more I will try that thanks !
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modvrs
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PostPosted: Wed Oct 11, 2023 16:22    Post subject: Reply with quote

Roughtrax and Millners do replacement nuts and sealing washers if you totally mangle yours
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colineddy
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PostPosted: Wed Oct 11, 2023 16:52    Post subject: Reply with quote

Yes get them thanks and they are going to have anti sieze on them before they go in.
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modvrs
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PostPosted: Wed Oct 11, 2023 17:48    Post subject: Reply with quote

I reckon just don't over-tighten them especially the drain plug, I'd rather have a bit of a struggle to get them out than risk them falling out.
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Andyk80
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Joined: 13 Feb 2022
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PostPosted: Mon Oct 16, 2023 15:38    Post subject: Reply with quote

I had a right nightmare with the front plug on mine.  Tried the same methods as you.  In the end, I was bathing it in penetrating fluid daily for a week or so and then ground a deep notch into one side of the plug.  With a decent depth notch, I ground an old chisel almost flat then hammered it in the direction needed to undo it, with occasional hits from a blowtorch and it finally popped free.  If you go down that route, make the notch quite deep or the chisel will just eat the metal (it's pretty soft unfortunately).
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