Rear Differential plug

Digger · Post by **Digger** » Fri Apr 08, 2011 8:13 am

OK I have an issuethe top plug on the Differential of my 05 AWD is stripped. the plug is on real tight and the hole stripped out when I went to take it off. Any one know of how I might get it off.The good news is I tried the top plug first. ( been in that movie before) the bad is now I can't change of add gear oil.

keithvibe · Post by **keithvibe** » Fri Apr 08, 2011 8:33 am

vise grip

star_deceiver · Post by **star_deceiver** » Fri Apr 08, 2011 9:56 am

So it spins freely in it's hole or did you round off the corners and the socket won't do jack?

Salsa Guy · Post by **Salsa Guy** » Fri Apr 08, 2011 1:12 pm

I heard those things were a PITA to remove.

Digger · Post by **Digger** » Fri Apr 08, 2011 1:13 pm

The plug is welded on. will not budge. starting a perpetrating oil bath. pray it daily for a while. the hole that the Allen wrench goes into is now round. I can get it with a small set of vise gripes but can not get much leverage on it. I think my big issue is how to get it unstuck.

455SD · Post by **455SD** » Sat Apr 09, 2011 3:36 am

Find a Torx bit socket that is just a bit bigger than the "rounded out" hole. Tap it in with a hammer, making sure to go the full depth of the hole. The splines of the Torx will dig into the rounded portion of the plug. It is imperative to get as much "grip" as you can. The penetrant bath is a good thing. Use something like PB Blaster. This stuff works wonders. Usually an overnight soaking will suffice. The one thing to keep in mind with using the Torx, is to not try to go too big. You don't want to "swell" the plug into the housing making it tighter. I have used this method many times in the past, especially on disc caliper bolts that have become one with the bracket.Good luck!

Digger · Post by **Digger** » Sat Apr 09, 2011 12:32 pm

I am worried that the threads on the case will come off with the plug.

star_deceiver · Post by **star_deceiver** » Sat Apr 09, 2011 12:34 pm

I doubt it. At worst you might strip them out and have to loctite the plug back in.

Digger · Post by **Digger** » Sun Apr 10, 2011 10:37 am

looks like a slow process to get it off. I will keep youal updated.

Digger · Post by **Digger** » Mon Apr 11, 2011 10:21 am

Got it off tonight. after hitting it with penetrating oil for a week. I jacked up the rear and set it on the jack stands. hit the plug with a hammer and then a chisel to try and move the bolt out/in to bust up the bond. Then I thought I would try my trusty channel locks. it worked. plug out oil changed. its been 50,000 mile since I changed it before and it looked nasty when it came out. Glad I kept trying and got it changed. Thanks all for the help

Salsa Guy · Post by **Salsa Guy** » Mon Apr 11, 2011 12:00 pm

Maybe a little anti-seize on the threads for next time. Glad to hear it

Digger · Post by **Digger** » Tue Apr 12, 2011 12:10 am

yep, I put some on this time.

Rear Differential plug

Rear Differential plug

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