Front Diff and Transfer Case Oil Change Howto

Yup.

Heat and penetrating oil - repeat. Hit the bolt with a ball peen hammer to shock the threads.

You can sometimes take the next larger sized Torx bit and hammer it into the hex bolt. Then use an impact driver.

A bolt extractor big enough to fit in the hex will also work. But when they get that fat, they get expensive. Same with left-hand drill bits.

 

@IslandYotaBoy - This here should do the trick if all else fails. You may need to drill a pilot hole through the allen head.

https://www.amazon.com/Stahlwille-9...1480630408&sr=8-1&keywords=m10+bolt+extractor

 

What do ya think @IslandYotaBoy ?

 

you guys are awesome is what I think ! haha.
So im gonna get a replacement on the plug on Amazon, and then to get it out, I need to drill a hole and then put that bolt extractor in and it comes out eh???

 

You only want to drill enough for the screw extractor to get a grip on the bolt. There's a magnet on the back of the bolt that you don't want to pop off and get stuck in your diff somewhere.

Don't forget to use oil/heat/tapping the threads BEFORE you try and use the extractor - or you may end up with a broken screw extractor stuck in your stripped drain plug.

 

So what would be the correct size to get (screw extractor)

 

M10-M12

See the link last page. 3/8" / M10 should do the trick.

 

Ok I hope it works

 

CAREFUL with the extractor!

You do not want to snap it off as it is very hard steel and will require a very hard drill bit to even dent it!

I'm surprised it stripped...mine felt like it was 10mm deep and with a little leverage came loose. it was an effort though..

Have you cleaned it out? Maybe you didn't get the wrench seated all the way in...maybe some grime in there you could clean out and perhaps get that sucker off!

Good luck!

W

 

LIFE.. I drilled the hole, then put in the screw extractor. And put maybe 40 pounds of force? Not a ton and bam! the thing broke right in half...
This whole thing is ridiculous.

 

about the only way to get a broken extractor out is EDM (electro-discharge-machining), which would require removing the whole assembly and bringing it to an EDM capable machine shop.

 

ok getting desperate. JB weld a nut on and take it out?????

 

Oh man!

JB weld will NOT hold the force needed to crack a stuck nut.

Can you screw out the extractor? or did it break at or below the surface? if below and you can get in there with a drill, drill around the easy out and see if you can pop it out. A carbide bit will punch through it too.

To properly use an easy out you have to drill out 90% of the bolt, almost just threads. Little late...sorry.

Do you have the replacement bolt/plug? If so make note of its depth and width of threads. You want to avoid introducing shavings into your diff. Use lots of lube and maybe a couple sizes of carbide bits to enlarge the hole without punching through. Also don't want to mess up the threads on the diff....!

Your easy out should be 75-90% of the width of the threads. Closer to 90% in your situation with a seized bolt.

I learned this lesson the hard way too.....

Good luck!

W

 

Son of a bitch @IslandYotaBoy, that sucks.

Did you cycle with heat, penetrating oil, shocking the threads?

Can you get a vice grip on the remainder of the extractor?

 

It broke off in a shitty place,I can't get it out either, I just posted a ad on craigslist to see if someone will weld a nut on for me.

 

damnit......

 

UPDATE!
Craigslist success, called this local welder who does fences etc.. He welded this 1" nut on for me and the heat plus the weld made it easy to come off! Came off, put on the new plug and bam! Life goes on.. $30 to the welder not too bad considering the shop said itd be 60-100 per hour to do it, which may have been more? Anyways just glad to be done with it.. Thanks guys

 

wow!

 

Glad to hear you had success.

I've read a few times on here about this happening. Being that most guys only change the fluids every 30-50 thousand miles they may go three or four years between servicing (depending on annual mileage) and the plugs can get pretty nasty and cause the same problems you've had.

My advice to avoid this is to get under the truck every several months and crack open the fill and drain plugs just enough to keep them from rusting etc....I'm not saying take them out, just loosen and re-tighten them. Obviously don't loosen them to the point that fluid comes out.

I, on the other hand, drive roughly 60,000 miles annually and do this service myself every 6 months and I never have a problem with the plugs....just my two cents.