diff fluid change help.... fill plug is stuck!

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  • Flood
    Advanced Member
    • Mar 2004
    • 105
    #1

    diff fluid change help.... fill plug is stuck!

    Went to change my diff fluid the other day and found that the fill plug is corroded and I cant get it out!
    I can't fit my 10mm hex bit socket into the hole because of the corrosion. I was thinking of filing down 10mm I had, but the hole looks allmost circular. Can't hammer it in because I'm using this (not enough room between the diff and the spare tire well)



    My friend suggested that I tap it with a left hand thread, and remove it using a left hand bolt. Sounds like a good idea, but I'm not sure if the plug is too hard to use a tap on, or if there is enough room between the diff and the spare tire well.

    I tried using some penetrating oil that usually gets corrosion off, but it did no good. Any recommendations? :?

    The best improvement you can do to a car is become a better driver.
    Tags: None
    • e30Matt
      R3V Elite
      • Dec 2003
      • 5077
      #2
      The way I did it was to find a bolt with the correct sized head, then thread two nuts onto it and lock them together. Then, use that to remove the drain plug.

      Either that, or use a head stud remover/installer to rotate it.

      "See, we're adding a little something to this month's sales contest. As you all know, first prize is a Cadillac Eldorado. Anyone wanna see second prize? Second prize is a set of steak knives. Third prize is you're fired."

        Comment

        • Flood
          Advanced Member
          • Mar 2004
          • 105
          #3
          Originally posted by e30Matt
          The way I did it was to find a bolt with the correct sized head, then thread two nuts onto it and lock them together. Then, use that to remove the drain plug.
          :?:
          But when I rotate it CCW, won't the two nuts just come off the bolt?


          Either that, or use a head stud remover/installer to rotate it.
          Can you explain this process? I've never used a head stud remover/installer

          The best improvement you can do to a car is become a better driver.

            Comment

            • e30Matt
              R3V Elite
              • Dec 2003
              • 5077
              #4
              It's a tool that has a round hole you put the stud through, and then a rotating cam that locks onto the stud when you rotate it. It attaches to a standard ratchet, breaker bar, etc.

              http://store.autotoolexpress.com/a-old2526.htmlThat's one.

              "See, we're adding a little something to this month's sales contest. As you all know, first prize is a Cadillac Eldorado. Anyone wanna see second prize? Second prize is a set of steak knives. Third prize is you're fired."

                Comment

                • Flood
                  Advanced Member
                  • Mar 2004
                  • 105
                  #5
                  cool, sounds like that'll do the trick. Thanks!

                  BTW, got a part number for a replacement fill plug?

                  The best improvement you can do to a car is become a better driver.

                    Comment

                    • e30Matt
                      R3V Elite
                      • Dec 2003
                      • 5077
                      #6
                      33 11 1 212 682 --> Fill plug
                      07 11 9 963 355 ---> Gasket ring

                      "See, we're adding a little something to this month's sales contest. As you all know, first prize is a Cadillac Eldorado. Anyone wanna see second prize? Second prize is a set of steak knives. Third prize is you're fired."

                        Comment

                        • EverWiser
                          Grease Monkey
                          • Aug 2004
                          • 313
                          #7
                          You could also buy an "easy-out"...It looks kind of like a tap but instead of threads it has left-wound flutes on the shaft. When you turn it CCW it will bite into the hole and hopefully break the plug loose. You might have to try a few times and/or find a way to drive it in a little to give it a better initial bite but it should work.

                            Comment

                            • Den
                              Advanced Member
                              • Mar 2004
                              • 162
                              #8
                              You might have some luck cleaning out the the hex recess in the fill plug with a pick.

                                Comment

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