Help, diff plug starting to strip!!!

[Maluco]

The last idiot to have tightened, did so tremedously. It has now starting to strip as I applied the pressure necessary to loosen the damn thing. Any recomendation on how to proceed without further stripping and therefore really being screwed? Thanks

[AdamF 88iS]

You mean it's rounding out the hex hole where the tool goes in?

My first attempt would be to take a chisel and try to hammer the plug loose by hammering it into rotation.

Second would be to try to get the seal washer out from under the plug with a small saw or something. If you get some of it out you will relieve most of the tightening torque on it.

Whatever you do, worse case scenario is you have to swap the diff cover which is not a big deal at all.

[browntown]

those internal hex's can be a b1tch. I've run into problems with the axle to differential bolts. Usually it's slime buildup in the hole that's preventing a proper seat of your hex socket. Clean the hole with a q-tip, be thorough. Use long 1/2 drive hex bits, with a breaker bar, and pb blaster.

Worst case if the hole is starting to round, you can take a size up hex and hammer it in. Worst case, weld the allen wrench into the hole. They shouldn't be torqued too hard.

Replace the plug once you get it out so you wont have to fight it next time.


Also, just remembered that some bmw diffs and axles have torx bolts (female). Sometimes a torx hole will look like hex until you really clean it.

[Maluco]

You mean it's rounding out the hex hole where the tool goes in?

My first attempt would be to take a chisel and try to hammer the plug loose by hammering it into rotation.

Second would be to try to get the seal washer out from under the plug with a small saw or something. If you get some of it out you will relieve most of the tightening torque on it.

Whatever you do, worse case scenario is you have to swap the diff cover which is not a big deal at all.

those internal hex's can be a b1tch. I've run into problems with the axle to differential bolts. Usually it's slime buildup in the hole that's preventing a proper seat of your hex socket.

That's exactly what caused me to start stripping it!! that and of course the idiot who overly tightened it previously.

Worst case if the hole is starting to round, you can take a size up hex and hammer it in. Worst case, weld the allen wrench into the hole. They shouldn't be torqued too hard.

Replace the plug once you get it out so you wont have to fight it next time.

Also, just remembered that some bmw diffs and axles have torx bolts (female). Sometimes a torx hole will look like hex until you really clean it.

All of those suggestions are great guys, I will try them all until one works. I'm sure one of them will. The only one that came to mind was the welding method but those others sound like they'd work as well. I'm sure there's a reason, maybe space? but why would they not just have used regular frickin bolts instead of those hex/torx.... I greatly appreciate the help guys. I will follow up just to post which worked first.

[emi325i]

I had trouble getting that out on the trans, but, in my case, it was due to corrosion. I torched it, and it came loose easily.

I also torched a few stubborn break line fittings which caused i series of small explosions, so perform this procedure at your own risk.