Tip for removing stubborn diff fill plug?

My rear diff fill plug looks like someone beat the snot out of it with an air tool. It's on there tight and the corners are slightly rounded, but probably salvageable. Any tips for getting it off? I've already tried penetrating oil and tapping the breaker bar with a hammer.

The problem is that the the bolt head is pretty shallow and when I tried to use a breaker bar to get enough torque on it, it seemed like the socket was going to slip off. There just wasn't enough bolt head material for the socket to hang onto.

I thought about hitting it with heat, but perhaps MAPP gas torch + diff oil = bad idea.

Ideas?

Thanks
Dave

 

Key word, TAPPING, NOT to be confused with Banging!!

 

Chris: how long would you tap w/ the hammer before switching to Plan B (to be determined)?

I tapped it for ~ 5 minutes. Tonight I'll give it another try.

(Ok, bring on all the sarcastic comments about TAPPING THAT!! FOR ONLY 5 MINUTES?)

 

6 point socket and grind (or turn on a lathe) the bevel off the end of the socket. The end of the socket that goes on the Drain Plug should be square so you get max bite on the bolt.....

There's plenty of bolt to get a bite on, just not enuf socket until the bevel is gone....

 

Just be patient with it and it should break loose. Turning the right way??

 

you have a new one (fill plug) at the ready, right?

 

vice grips and a hammer

 

why not? The drain plug sticks down enough. They make big enough vice grips...The fill plug, Im not too sure about..

I just changed this fluid like 2 days ago, and i cant remember if the fill plug was sticking out enough or not...Almost positive the drain plug is though.



My bad...I knew it was sticking down..lol...Forgot it had a case around it.

 

put ATF fluid on the bolt and just give time, second make sure you have tighest fit socket you can find... 6 point would be the best.

 

go tow something big and get that rear end red hot...then try tapping it with a BFH

 

i find that if you sometimes switch from a 12 pt wrench to a 6 pt, or vice a versa..you can get more bite. hell, i have even gone to a tight standard sized socket and tapped them on. all these move have a distinct "point of no return".

 

Others have just asked the Dealer to help get it lose...most do it for free.

 

Pick up a new plug, then get someone to weld a nut or old lug nut to the plug. You should have no issues getting the plug out after this.

 

For a rounded-off bold that you can't get purchase on you can try using a drift punch and hammer. You will probably have to tap from several different angles but eventually the bolt should start to move. An alternative is to file a couple of new parallel flats and then use an open-ended wrench and hammer. I had to do this a lot when I worked for one farmer who seemed to think that a 24" pipe wrench was the only tool they made.

 

PENETRATOR LUBE!!!! All jokes aside I was being serious. I use PB Blaster and a 3/8" ratchet with a 6 sided socket. No hammers no BS, just getting the job done.

Worst case scenario would be to heat it slightly it and give the plug a solid wrap with a small ball-peen hammer.

 

That's what I would do.