Rear differential drain plug stuck
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Freshman User
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Rear differential drain plug stuck
I've been doing some general maintenance on my new bronco (1986 4x4, v8 302, automatic with overdrive) and now Im stuck at the rear differential. I cant get the darn plug loose.
I see the drain plug (the one which is a hollow square that a 3/8" drive socket goes into) but i cant get it to budge. it is completely stuck. I cleaned up the bolt, heated it up, used a big breaker bar, let it soak in penetrant, still not budging. The 3/8" socket is a little loose in the plug, is there a better tool for the job? I dont want to strip it and be royally stuck!
Any help appreciated
I see the drain plug (the one which is a hollow square that a 3/8" drive socket goes into) but i cant get it to budge. it is completely stuck. I cleaned up the bolt, heated it up, used a big breaker bar, let it soak in penetrant, still not budging. The 3/8" socket is a little loose in the plug, is there a better tool for the job? I dont want to strip it and be royally stuck!
Any help appreciated
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Freshman User
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oops
Well here's an update; the plug is now stripped and mangled, so I am screwed. Are there "stripped bolt extractor" type tools made for these type of plugs (plugs that take a male tool)? Are diffs expensive from junkyards?
Looks like im just going to have to drive it until it blows i guess, unless i can get that plug out somehow... any input appreciated!
Looks like im just going to have to drive it until it blows i guess, unless i can get that plug out somehow... any input appreciated!
Senior User
Joined: Jan 2004
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From: Minneapolis, MN
Another option may be to remove cover and add a fill plug to the cover by drilling, tapping, and using a pipe plug. You should be able to see the normal level by observing where the line is when cover is removed (like looking at your dipstick). I am not sure how thick the metal is on the cover, however this might be a better option than replacing the whole unit with a junkyard one. Perhaps you could just get the cover from the junkyard and experiment with this prior to removing yours. If it works, you can just use the junkyard cover.
Good Luck!
Good Luck!
Cargo Master
Joined: Aug 2004
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From: Lynnwood, WA
Originally Posted by maxt
Well here's an update; the plug is now stripped and mangled, so I am screwed. Are there "stripped bolt extractor" type tools made for these type of plugs (plugs that take a male tool)?
Are diffs expensive from junkyards?
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Joined: Feb 2005
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as for refilling it instead of tapping the cover or replacing the rearend ive seen people put the proper amount of fluid in a big ziplock baggie and place it in the dif and close the cover...as soon as you move the truck the bag will burst and in a few miles the bag will be gone... handy trail fix too... always good to bring ziplocks with on trail runs
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Wow, I dont think i'd have the cojones to leave the ziplock in there.
I ended up going to a local mechanic/tire shop and had them weld a 1/2" bolt to the plug that was stripped. No more problems taking off that diff plug
I ended up going to a local mechanic/tire shop and had them weld a 1/2" bolt to the plug that was stripped. No more problems taking off that diff plug
Elder User
Joined: Jan 2005
Posts: 656
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From: Houston
It is a $%^ when you are upside down. bolts just don't turn the same way. Good luck I have done it too
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Posting Guru
Joined: Nov 2004
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From: N. Gwinnett Co. Georgia
If your plug still has integrity and no leaks, go with the rear cover plug addition, makes the most sense. If you have to run a light bead around it to seal it forever with a mig torch. CAUTION: Make sure the ground is as physically near the plug as you can get it. Don't ground where the bearings/gears in the diff could arc causing damage. Using a pipe plug will give you an external square purchase point for removal. I wouldn' t replace the differential for a plug if not other damage is evident.
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Elder User
Joined: Jul 2003
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From: VB. Virginia
If you can't get the plug out remove the rear cover to get the old oil out, then refill the rearend by pulling the hose off you axle vent and put you new fluid in through the vent hole. I picked up an aluminum cover from a 2000 Explorer on ebay for $15.00 machined the brackets off for the Explorer now I have a nice cover with a fill plug and a drain plug.
Cargo Master
Joined: Aug 2004
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From: Lynnwood, WA
Originally Posted by maxt
I ended up going to a local mechanic/tire shop and had them weld a 1/2" bolt to the plug that was stripped. No more problems taking off that diff plug
Elder User
Joined: Jul 2004
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From: Fredericton NB, Canada
Originally Posted by bigbroncojeff
as for refilling it instead of tapping the cover or replacing the rearend ive seen people put the proper amount of fluid in a big ziplock baggie and place it in the dif and close the cover...as soon as you move the truck the bag will burst and in a few miles the bag will be gone... handy trail fix too... always good to bring ziplocks with on trail runs
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