Removing Fill Plug
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New User
Joined: Dec 2003
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Removing Fill Plug
Drained all the rear end fluid in my 97 Expedition, the limited slip seemed to be binding around corners after it got hot (40+ mile trips)
Ok, so now I've got the fluid drained but I can't get the fill plug out. I've always used a 3/8" drive ratchet but on this one its starting to strip it so rather than make a bad situation worse I stoped. I sprayed some liquid wrench on the outside we'll see if that breaks a little of the rust.
Is there a special drive tool for removing these plugs? If I can't get this out any other options?
Thanks
Ok, so now I've got the fluid drained but I can't get the fill plug out. I've always used a 3/8" drive ratchet but on this one its starting to strip it so rather than make a bad situation worse I stoped. I sprayed some liquid wrench on the outside we'll see if that breaks a little of the rust.
Is there a special drive tool for removing these plugs? If I can't get this out any other options?
Thanks
Hotshot
Joined: Oct 2003
Posts: 17,799
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From: Ashland City, TN
Might have to go with channel locks to get it off and put in a new plug...
I'm thinking it could be threaded backwards. But I doubt that.
Are you useing a socket that fits the nut. or a star like patterned socket?
I'm thinking it could be threaded backwards. But I doubt that.
Are you useing a socket that fits the nut. or a star like patterned socket?
Elder User
Joined: Oct 2003
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The quick change place stipped mine with a 3/8 inch socket extension and I heard that Ford has a special tool for doing the job correctly.
After my was stripped- another shop welded a bolt head into mine so I could remove the plug. The guy at this shop said you can replace the square indented plug with another common plug available at any plumbing supply shop.
Never did it myself, cause the welded setup works fine for me.
After my was stripped- another shop welded a bolt head into mine so I could remove the plug. The guy at this shop said you can replace the square indented plug with another common plug available at any plumbing supply shop.
Never did it myself, cause the welded setup works fine for me.
Freshman User
Joined: Aug 2003
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From: zanesville ohio
tight plug
007 just changed mercon fluid in my 1995 transfer case i had same problem i was able to take my prophane [ spelling]torch an heat at edge of plug came right out just be careful don,t want read about u in news tomorrow jack
Postmaster
Joined: Dec 2003
Posts: 2,659
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From: S/C Texas
Ford sure didnt do the plugs right. The drain plug for my transfer case is stripped. Its one of those indented socket end things. Seems to me that a regular bolt could have worked just fine. Any ideas how to get it backed out of there?
Senior User
Joined: Sep 2003
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Would one of those screw/bolts extractors big enough work? Or if you couldn't get ne big enough you could drill a hole in the center of the plug and use a smaller extractor. If course, I guess you'd have fluid spraying at 'cha, so maybe that wouldn't be a good idear.
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I thought about the screw extractor thing but then it occured to me that some of the metal shavings from drilling may end up inside if I went to far. I tried to get a vice grip on it, no use. I ended up welding a bold into the stipped out hole, worked like a champ. They do sell a tool. NAPA had a picture of one but it would have taken several days to get.
