%&#@ing diff filler plug!

[Bazzateer]

I'm now soaking in the bath, aching from head to toe, feeling very sorry for myself having tried and failed to undo the diff filler plug.
The gearbox was a little low when I checked it (now topped up) so I thought I'd better check the diff as well. Can't shift it. Tried hitting the spanner with a heavy hammer, tried penetrating oil, tried heat (may not have give it enough?), tried a length of pipe on the spanner, tried hitting the length of pipe with the hammer, tried hitting my knuckles with the hammer several times. Nothing. I've only got normal sized open ended spanners so I've ordered a foot long one to see if increased leverage will work.
Can't get the windy gun on it because of the rear diff carrier and really don't want to take it all apart.
With heat what should I focus on, the plug itself and go for cherry red or the casing around it in the hope the alloy will expand quicker and release the plug?

 

[jonbills]

is it a square male plug? I'd get a square socket for it and use a breaker bar and heat on the case.
(trouble with the heating bit is that your heating the diff oil too, so it can take a lot of heat)

 

[Rob Gaskin]

I had to dismantle my rear diff carrier on one car to get enough access to undo the plug and even then it was very very difficult. Do you ever think that people running modern cars and getting them serviced are missing out on all this 'fun'?

 

[Bazzateer]

is it a square male plug? I'd get a square socket for it and use a breaker bar and heat on the case.
(trouble with the heating bit is that your heating the diff oil too, so it can take a lot of heat)

It is square, same as the gearbox filler, both 17mm. Breaker bar would be good (I have one) but I don't think a socket and breaker bar will fit, hence me using a spanner. I need to get it up higher so I can use a longer spanner with a piece of pipe on it for extra leverage.

 

[Bazzateer]

I had to dismantle my rear diff carrier on one car to get enough access to undo the plug and even then it was very very difficult.

This is what I'm hoping to avoid.

 

[Paul_S]

I hope you get the thing undone somehow...

So I have a question - when refitting said plug, other than overtightening it, what else can be done to help remove it later? Would it be a good or bad idea to use a little smear of copper slip on the thread for example?

 

[AliK]

Baz, sorry to hear that, if any consolation I too smacked my poor little finger’s second l cills with a lump hammer when I missed the spanner!!! Serves me right for not realising it was the wrong way for a left hand thread!!

The socket should absolutely fit and you should be OK with a breaker bar. Try again tomorrow with a fresh brain and body oh and some self penetrating oil.

 

[RyanT]

Had this earlier this week, it was completely mashed.

Had to drop the diff, smash a socket on it and use the impact gun - Then reshape it with a file.

 

[Alphabettispaghetti]

if it helps, if you heat the alloy, i'll pop round with my ice cold wit and freeze the plug to break the bond?

 

[Bazzateer]

Baz, sorry to hear that, if any consolation I too smacked my poor little finger’s second l cills with a lump hammer when I missed the spanner!!! Serves me right for not realising it was the wrong way for a left hand thread!!

The socket should absolutely fit and you should be OK with a breaker bar. Try again tomorrow with a fresh brain and body oh and some self penetrating oil.

That looks like the drain plug. Not even tied that yet. Want to get the filler plug out first.
This is my hurty finger:

 

[Bazzateer]

Had this earlier this week, it was completely mashed.

Had to drop the diff, smash a socket on it and use the impact gun - Then reshape it with a file.

I DO NOT want to have to do that!

 

[Bazzateer]

if it helps, if you heat the alloy, i'll pop round with my ice cold wit and freeze the plug to break the bond?

I'll try anything!

 

[AliK]

Ouchie!! Sorry I misread tour post - my misunderstanding !!

 

[Paul_S]

Had this earlier this week, it was completely mashed.

Had to drop the diff, smash a socket on it and use the impact gun - Then reshape it with a file.

Nicely done! How did you get it so square with just a file?

 

[Paul_S]

Out of interest, is there a proper tool available for the filler plug? Or do you just use an open ended spanner?

 

[Graeme - CZ]

Out of interest, is there a proper tool available for the filler plug? Or do you just use an open ended spanner?

There is. It’s the same plug on the side of the gearbox too. I had to order mine from Japan - £40 - £50 landed in the UK. Let’s see if I can find my old eBay link.


Sent from my iPhone using Tapatalk

 

[Graeme - CZ]

There is. It’s the same plug on the side of the gearbox too. I had to order mine from Japan - £40 - £50 landed in the UK. Let’s see if I can find my old eBay link.


Sent from my iPhone using Tapatalk

https://www.ebay.co.uk/itm/221709332289


Sent from my iPhone using Tapatalk

 

[Graeme - CZ]

I'm now soaking in the bath, aching from head to toe, feeling very sorry for myself having tried and failed to undo the diff filler plug.
The gearbox was a little low when I checked it (now topped up) so I thought I'd better check the diff as well. Can't shift it. Tried hitting the spanner with a heavy hammer, tried penetrating oil, tried heat (may not have give it enough?), tried a length of pipe on the spanner, tried hitting the length of pipe with the hammer, tried hitting my knuckles with the hammer several times. Nothing. I've only got normal sized open ended spanners so I've ordered a foot long one to see if increased leverage will work.
Can't get the windy gun on it because of the rear diff carrier and really don't want to take it all apart.
With heat what should I focus on, the plug itself and go for cherry red or the casing around it in the hope the alloy will expand quicker and release the plug?

I’ve been there. Had to buy one of these in the end.


https://www.ebay.co.uk/itm/221709332289


Sent from my iPhone using Tapatalk

 

[Bazzateer]

£65 delivered!? Bloody hell!

 

[Paul_S]

£65 delivered!? Bloody hell!

I've not found a UK equivalent.

Could someone make these "locally"? Group buy perhaps?