stripped the fill plug on rear diff

so like the title says i stripped the fill plug on the rear diff after changing the fluid today. thankfully its not the drain plug that stripped. anyway, when i went to replace the fill plug it got tight but then broke loose and will not tighten down now. i know i know. too tight. also, it will not back out if i put the socket drive in reverse. i drove around a little and the plug is keeping all the fluid in the rear diff. i guess only bc the plug it at the top of the fluid level. as it stands now the plug is all the way in only hand tight and no fluid is leaking. so now what do i do. do i try to remove the fill plug by using vise grips and pulling out on the plug while i unscrew it? should i buy a new plug before attempting this since the threads are already damaged? what are the chances it is only the plug. could i have stripped out the threads on the rear diff itself, or is the metal the diff is made from stronger than the bolt and it is in fact only the bolt that is stripped??????

 

The bolt is a very soft metal. So chances are that you just need a new plug. You can get one a any parts store.

To remove, try to unscrew it while pulling on it.

 

36 ft/lbs. That's really not a lot.

 

keeping my fingers crossed that it is only the plug. could i have damaged the threads in the diff or should i sleep easy knowing the plug is softer metal and it is only the plug that is stripped???

 

Yes, you should be fine. The diff is made from pretty hard steel and the plug is very soft. Just clean the threads (on diff) , making sure there is no metal pieces in the threads before you install the new plug.

 

When you pull out the plug, it will tell the story. If you see flat threads on the plug and not on the diff, easy fix. Messed up threads on the diff, not easy fix.
If diff: Get a Keen-Sert to replace the threads. DO NOT use a Heli-coil, it will back out. Keen-Sert, or locking inserts work best. They use standard drill bits and tap sizes, not oddball stuff like helicoil does.
Make sure there is enough meat on the diff before you get the parts and drill. I have used this fix elsewhere, not 100% sure it will work on the diff.

 

I have only used Heli coils, but agree they will not work (reason stated above). When you drill and tap into the housing, make sure the flush the diff really well to get the shavings out.

 

R&R your fluid after you get the plug out & pray you get any metal shavings,threads,etc; out, soft metal or not you are going to be double fucked if this shit gets thrown into diff gears (ring & pinion,etc

 

Si. Or if you want OP: you can remove the 3rd member then dill and tap or what ever, then clean it all up really well and reinstall 3rd member (make sure you replace the gasket).

 

Flexible arm magnet to remove the remaining shavings.

 

There should be enough room to weld a new nut on top of the fill hole and install a new bolt. Pic?

 

X2 you will need a new plug but in will be ok. i would drain strain&refill.

 

Did you ever get your plug out and get it fixed? I just did the same thing I was using a torque wrench, but apparently it doesn't work anymore...

 

Worst case scenario, leave the cross-threaded fill plug in place, and fill using the breather hole in the future.

 

If you can get a screw driver under the head you can pry up on it while you try to back it off with a socket or a wrench.

 

weld it......

 

I have a new bolt on order from the dealer, still have to get the stripped one out and hope it was only the bolt and not the diff threads...

 

If all else fails you can just leave the plug in, if it leaks seal it up with jb or weld it, and then just fill the diff with exact amount from the breather hole.

 

I doubt that its possible to fill from the vent. The gear oil will plug it and there is nowhere to vent the pressure off from. You'd have to drill/tap a second vent hole to do this successfully.

 

I don't. It's been done before. It'll be slow but it'll work. Can always stick a small piece of tubing into the hole along side the tip of the bottle for a breather.