Frozen/Stripped Differential Fill Plug


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Avalon97
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Frozen/Stripped Differential Fill Plug

Post by Avalon97 »



Recently purchased a 1996 Aspencade with no verifiable maintenance records. Went to drain the rear differential and found the fill bolt to be stripped. This could be a good or bad sign as obviously someone either changed or attempted to change the oil prior to me. Tried heat and vice grips but just compounded the problem. Does anyone have any suggestions how I can get the plug out? I'm no mechanic, just someone willing try. Thanks.



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golden highway
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Re: Frozen/Stripped Differential Fill Plug

Post by golden highway »

I assume you are talking about the fill cap about the size of a quarter. It only has a few threads and an oring. I never seen one that stuck. usually the threads on the cap break away from the cap. At worst you should be able to pop it out with a big screw driver. You can buy new ones on eBay for a few bucks so take a dermal and cut it if you have to.

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ct1500
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Re: Frozen/Stripped Differential Fill Plug

Post by ct1500 »

Let us hope you are on the large fill plug and not something else.

Interesting problem. A plug that is stripped needs some outward force (while turning) to hopefully catch a semi decent thread to begin the back out process.

Large vise grips while turning and pulling straight outward would be first choice. Next choice would be to drill hole in center of hex and install a convenient tool to hook inside of plug. With various leverage devices pull hard out on tool and at same time turn plug counter clockwise with open end wrench.

Will be much easier with 2 pairs of hands. Proper flush and catch of any shavings observed of course.
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golden highway
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Re: Frozen/Stripped Differential Fill Plug

Post by golden highway »

I would be concerned about using heat. I know the plug oring would melt but what else in rear would be effected?

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Re: Frozen/Stripped Differential Fill Plug

Post by Wingsconsin »

This one....?!?

Image


Hopefully you said YES...
Be careful about drilling or cutting this on off. The shavings and bits and pieces could go into your final drive and cause problems.
You would then need to do a really major flush out and even then I would be nervous...
Go to a BIX BOG or hardware store and find "GripTite" sockets.
They can be used on a breaker bar or long socket and may give you enough leverage to get that cap started...
Spray PB Blaster on the joint of the Plug cap and the final drive housing liberally
Breaking the cap is OKAY as they are cheap enough to buy...damaging a final drive will be costly



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Your results may vary. Universal disclaimers apply.


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ct1500
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Re: Frozen/Stripped Differential Fill Plug

Post by ct1500 »

A little confused now.

Are the threads stripped and plug just rotating or is the plug HEX stripped which will not allow a wrench on it. :?:

If the hex is stripped a couple light taps with a hammer and chisel on the outside shoulder in a loosening fashion of the plug will get it free. There is plenty of meat to bite into. :D
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Re: Frozen/Stripped Differential Fill Plug

Post by thrasherg »

I too am assuming that the hex nut in the middle is just rounded off. As stated use a cold chisel and just tap the very outer edge of the nut to rotate it in a counter clockwise direction. There is plenty of metal there and if you damage it, just move round a bit further and try again. You will need to buy a new one obviously but it should not be hard to get it out, I would NOT suggest using heat as there is a lot of oil around there that could catch fire and also that nut cannot be done up very tight as it really is made of pretty poor aluminum.

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peppilepew
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Re: Frozen/Stripped Differential Fill Plug

Post by peppilepew »

The best way is an air chisel. Lightly chisel the outer rim of the plug while attempting to loosen with special sockets to grip stripped area. Works on transmissions just about every time. We get lots of experience with stuck fasteners here in the North east.

Avalon97
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Re: Frozen/Stripped Differential Fill Plug

Post by Avalon97 »

Thanks everyone for your suggestions!! This website is great. The hex head is indeed rounded not stripped, I wasn't clear on the problem in my post, but I am confident now, that I will be able to get it out. As I am working in an unheated garage in the middle of winter, I will be taking my time and making sure I do it right.
Thanks again!!

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Happytrails
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Re: Frozen/Stripped Differential Fill Plug

Post by Happytrails »

Mine was super tight when I went to service it recently. Someone gave it a big pull when they tightened it. Torqueing it to spec only took a light pressure.
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soulman76
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Re: Frozen/Stripped Differential Fill Plug

Post by soulman76 »

So glad I found this thread. I would have been lost without it.
Chisel and hammer method shredded the plug, but finally got it out. New plug in now.
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CrystalPistol
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Re: Frozen/Stripped Differential Fill Plug

Post by CrystalPistol »

My 1200's was leaking around that plug, I had just bought it when I discovered it. I decided to do a lube change, found the outer portion of the aluminum fill plug that holds O-ring was cracked from over tightening some time. I bought a new fill plug & drilled a hole across the hex head (where it wouldn't break through to leak) & reinstalled it just snugged it with the O-ring in place & safety wired it with loop of soft # 12 bare copper wire up over the vent cap boss.
.… rear differential ... fill bolt …. stripped …. mechanic
:D
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curtm
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Re: Frozen/Stripped Differential Fill Plug

Post by curtm »

Yup use the chisel and hammer method, get a new plug, the reason this happens is someone probably did not put a little oil on the o ring, if you do not the o ring will seize the plug ,same thing that happens to a oil filter, always use you're finger and wipe a little oil on the oring

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pidjones
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Re: Frozen/Stripped Differential Fill Plug

Post by pidjones »

Had to use hammer and chisel on the alternator bolt plug on my '79. Luckily, I had a spare from the junk that I had bought. It's the same part.



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