It all started about a month ago when I went to change the rear diff fluid...
I went to remove the filler plug and it just spun. I didn't attempt to remove it because I wasn't sure if it was the plug or hole that was stripped. I assumed it was the plug because the hole is more durable. I went to my local dealer and was able to purchase a couple filler plugs. Went back home drained the oil and then tried to remove the filler plug. Well it didn't want to come out. It just spun both ways. I pulled out while loosening it and it wouldn't come out...
Long story short I ended up drilling the plug out (probably not the best way but was in a bit of a hurry). Found that the plug and the holes were both stripped. Looking at the filler hole I thought I could tap it. Went down to Harbor Freight, bought a tap and die set and was actually able to re-tap the hole. When I put the new filler plug in I didn't use a torque wrench because I didn't want to tighten it too much and strip the new "more fragile" hole. I just hand tightened it snug.
All was good until today when I noticed the filler plug leaking. Well I assumed the plug became loose because it wasn't properly torqued. So I went to re-tighten the plug just now using care not to strip it and again it is just spins. I didn't attempt to loosen it because I don't want to remove the plug and the be unable to put it back it. There isn't a lot of oil leaking but it definetely needs to be fixed.
So what are my options now?
Should I attempt to re-tap the hole?
Should I take it to a professional?
Should I run it off a cliff and start over?
Should I weld the existing filler plug closed and tap a new hole???