Differential plug stuck
Fleet Owner
Joined: Aug 2010
Posts: 21,253
Likes: 1,656
From: Reynoldsburg, Ohio
You don't say what motor you have but if its that challenging for you just don't drive over 50K miles after a plug change.
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Cross-Country
Joined: Nov 2014
Posts: 73
Likes: 1
I had another go at it today. Hammer impact driver didn't budge it. Long torque wrench didn't budge. Finally the electric impact stripped the head.
Yukon's site doesn't give a price for their covers.
I'm thinking that maybe I can remove my cover, drill a hole at the proper level and weld a jam nut inside for a plug or have a rivnut installed.
A quick search on eBay reveals several covers with level plugs which look to be the same bolt pattern as mine. Most are listed to fit a Mustang, but I guess an 8.8 diff is always an 8.8 diff.
Yukon's site doesn't give a price for their covers.
I'm thinking that maybe I can remove my cover, drill a hole at the proper level and weld a jam nut inside for a plug or have a rivnut installed.
A quick search on eBay reveals several covers with level plugs which look to be the same bolt pattern as mine. Most are listed to fit a Mustang, but I guess an 8.8 diff is always an 8.8 diff.
Logistics Pro
Joined: Oct 2014
Posts: 3,677
Likes: 172
There is a video on youtube about different covers and how there shape affects the flow of the gear oil at different speeds and demonstrates how some aftermarket covers cause aeration of the oil at high speeds. probably not a good idea to weld anything inside the current cover. Why don't you try having a short 3/8 drive extension welded to the plug and try to remove the plug while it is still hot from the welding?
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Cross-Country
Joined: Nov 2014
Posts: 73
Likes: 1
That is a nice explanation of fluid dynamics. Too bad that his company doesn't make a cover to fit, not that I'd shell out $400 for one.
I find plenty of options for covers, very few of which have fill plugs.
The only other option is to leave the oil in it and wait for it to go crunch.
I find plenty of options for covers, very few of which have fill plugs.
The only other option is to leave the oil in it and wait for it to go crunch.
Fleet Owner
Joined: Aug 2010
Posts: 21,253
Likes: 1,656
From: Reynoldsburg, Ohio
That is a nice explanation of fluid dynamics. Too bad that his company doesn't make a cover to fit, not that I'd shell out $400 for one.
I find plenty of options for covers, very few of which have fill plugs.
The only other option is to leave the oil in it and wait for it to go crunch.
I find plenty of options for covers, very few of which have fill plugs.
The only other option is to leave the oil in it and wait for it to go crunch.
Amazon has them listed here:
Considering how heavy these are that's a fair price. Replace your existing cover with one of those, work on removing and replacing the factory drain plug and keep it laying around in case you ever sell the van.
Fleet Mechanic
Joined: Oct 2012
Posts: 1,558
Likes: 26
From: Bay Area
Nice differential cover JWA. When my fan hits 200k miles, I will get a cover like this. I drive 10k per year and the van is now at 110k miles. If I take your advice about not driving over 50k miles for the spark plugs, and apply the same logic to routine maintenance, I will never have to do any maintenance on my van.
I follow a similar maintenance schedule like you. The first thing I do when I get a new used van is spark plugs, oil and transmission fluid change, differential fluid change, radiator flush, etc. Then I keep on a strict preventive maintenance schedule for the life of the vehicle.
I follow a similar maintenance schedule like you. The first thing I do when I get a new used van is spark plugs, oil and transmission fluid change, differential fluid change, radiator flush, etc. Then I keep on a strict preventive maintenance schedule for the life of the vehicle.
Fleet Owner
Joined: Aug 2010
Posts: 21,253
Likes: 1,656
From: Reynoldsburg, Ohio
Nice differential cover JWA. When my fan hits 200k miles, I will get a cover like this. I drive 10k per year and the van is now at 110k miles. If I take your advice about not driving over 50k miles for the spark plugs, and apply the same logic to routine maintenance, I will never have to do any maintenance on my van.
I follow a similar maintenance schedule like you. The first thing I do when I get a new used van is spark plugs, oil and transmission fluid change, differential fluid change, radiator flush, etc. Then I keep on a strict preventive maintenance schedule for the life of the vehicle.
I follow a similar maintenance schedule like you. The first thing I do when I get a new used van is spark plugs, oil and transmission fluid change, differential fluid change, radiator flush, etc. Then I keep on a strict preventive maintenance schedule for the life of the vehicle.
Since so many of us here are DIY driveway mechanics and not turning wrenches for a living will find some tasks more time-consuming. Honestly a few times I've changed my own plugs its taken upwards of 8 hours. 
Naturally that's not staying with the job, I remove parts to make the job easier for me, take many breaks along the way which partially explains that. The rest of the explanation is I'm just never in a hurry doing anything myself. It seems we both like to start ownership of a "new" vehicle knowing what's been done most recently. Initially that might cost a bit more but its well worth it having that piece of mind.
The Yukon Gear differential cover is a nice part, perhaps a bit of overkill but I'm okay with that---if it makes DIY maintenance easier its a small price, IMHO.
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Cross-Country
Joined: Nov 2014
Posts: 73
Likes: 1
Thanks, that is a nice cover. However, it doesn't fit my diff. Mine has a more symmetric cover. It seems that virtually all the covers with level plugs are the other type.
I'm not really worried about future service, I or the van will be dead long before I need to change the fluid again. Had I been able to remove the plug from the diff I wouldn't even be looking for a cover with a plug.
Perhaps this one https://www.ebay.com/itm/363480602306?_trkparms=aid%3D111001%26algo%3DREC.S EED%26ao%3D1%26asc%3D20160811114145%26meid%3D3f285 cb0f65c4ad4848e72fb0f847696%26pid%3D100667%26rk%3D 2%26rkt%3D8%26sd%3D373561342207%26itm%3D3634806023 06%26pmt%3D0%26noa%3D1%26pg%3D2334524%26brand%3DPr oform&_trksid=p2334524.c100667.m2042
Or this https://www.ebay.com/itm/333846300306?fits=Make%3AFord&hash=item4dbaca4692: g:hH8AAOSwD9Vf8nkc#vi-ilComp
I'm not really worried about future service, I or the van will be dead long before I need to change the fluid again. Had I been able to remove the plug from the diff I wouldn't even be looking for a cover with a plug.
Perhaps this one https://www.ebay.com/itm/363480602306?_trkparms=aid%3D111001%26algo%3DREC.S EED%26ao%3D1%26asc%3D20160811114145%26meid%3D3f285 cb0f65c4ad4848e72fb0f847696%26pid%3D100667%26rk%3D 2%26rkt%3D8%26sd%3D373561342207%26itm%3D3634806023 06%26pmt%3D0%26noa%3D1%26pg%3D2334524%26brand%3DPr oform&_trksid=p2334524.c100667.m2042
Or this https://www.ebay.com/itm/333846300306?fits=Make%3AFord&hash=item4dbaca4692: g:hH8AAOSwD9Vf8nkc#vi-ilComp
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Fleet Owner
Joined: Aug 2010
Posts: 21,253
Likes: 1,656
From: Reynoldsburg, Ohio
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