*&%$# fill plug
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Elder User
Joined: Apr 2005
Posts: 882
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From: Wichita
*&%$# fill plug
I was trying to treat my Aero to some fresh Mobil 1 gear oil. I drained, cleaned the cover and tried to remove the fill plug to add fresh oil.
Well that thing won't budge. I tried Liquid Wrench and an impact gun but no luck. I'm going to let the Liquid Wrench do it's magic over night and try again tomorrow. That means I have to drive the old Dodge van to work tomorrow.
Moral of the story - if you tackle this job, make sure you can get the fill plug off before you drain the rear. I was lucky to have a backup vehicle!
Well that thing won't budge. I tried Liquid Wrench and an impact gun but no luck. I'm going to let the Liquid Wrench do it's magic over night and try again tomorrow. That means I have to drive the old Dodge van to work tomorrow.
Moral of the story - if you tackle this job, make sure you can get the fill plug off before you drain the rear. I was lucky to have a backup vehicle!
Posting Guru
Joined: Jul 2004
Posts: 2,416
Likes: 1
From: Mitchell, SD
Was the dif hot or cold? (ie ran alot before you tried to remove the bolt, or sat all day?)
If you can't get it off tomorrow, you might want to try heating the bolt with a torch.
Good luck VanGo and maybe you won't need to hit the shift key and the number keys!
If you can't get it off tomorrow, you might want to try heating the bolt with a torch.
Good luck VanGo and maybe you won't need to hit the shift key and the number keys!
Senior User
Joined: Nov 2007
Posts: 192
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From: Illinois, usa
Consider this a blessing in disguise.. the diff. will now drain ALL of the old fluid
out, considering it will sit all night...I did just this on my mobil 1 swap
on a jeep, next day, the internals actually looked clean, that is a heavy oil
in there that pours soooo slow.
good luck- heat around the bolt, not on it, that can help a little, it sets up
a more favorable heat expansion.
( if you ran a hot flame like oxy/actyl, and nailed only the bolt with heat,
it will expand while the surounding threads have NOT done so as much,
so it's a worse condition than no heat at all)
(( on an old benz, it is common to have to use your legs on the wrench, it is that tight/rusty..that's scary))
out, considering it will sit all night...I did just this on my mobil 1 swap
on a jeep, next day, the internals actually looked clean, that is a heavy oil
in there that pours soooo slow.
good luck- heat around the bolt, not on it, that can help a little, it sets up
a more favorable heat expansion.
( if you ran a hot flame like oxy/actyl, and nailed only the bolt with heat,
it will expand while the surounding threads have NOT done so as much,
so it's a worse condition than no heat at all)
(( on an old benz, it is common to have to use your legs on the wrench, it is that tight/rusty..that's scary))
Post Fiend
Joined: Oct 2005
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From: Kiev, Ukraine
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Senior User
Joined: Jan 2004
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From: Petaluma, Ca.
My '97 shorty has 96,000 and I'm sure the diff oil has never been changed. What is recommended?
Having done the gentle flush on the tranny and changed the plugs, I want to change the power steering fluid and the diff oil.
Beaned
Having done the gentle flush on the tranny and changed the plugs, I want to change the power steering fluid and the diff oil.
Beaned
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Postmaster
Joined: Sep 2003
Posts: 4,452
Likes: 1
From: Southern California
"He who opens cover before fill plug has big trouble." .... Chinese Fortune Cookies 
Sorry Vango, but I couldn't resist.
I am with Bozzzzzzzzz, PB Blaster has never failed me yet, even on tough exhaust bolts. Just let it soak overnight. WD-40 is worthless IMHO.
Sorry Vango, but I couldn't resist.
I am with Bozzzzzzzzz, PB Blaster has never failed me yet, even on tough exhaust bolts. Just let it soak overnight. WD-40 is worthless IMHO.
Post Fiend
Joined: Apr 2005
Posts: 5,720
Likes: 5
From: Washington state
beaned,
any 80w90 differential gear oil
add a limited slip friction modifier if you have the limited slip rear end with clutch pack
low cost store bottles are fine if no towing or heavy loads. 80w90 weight
Valvoline makes a good mid cost 75w90 that is part synthetic and has the limited slip additive already
Mobil 1 makes a top line 100% synthetic base oil 75w90 that has the limited slip additive
good for heavy towing apps.
do not use a 80w140, too thick for these diffs, too much power loss.
wipe the bottom of the diff housing out with a rag saturated with gas or acetone. removes the settled out fine metal cuttings and debris that sticks to the case. i use acetone, wipe the seal surfaces first on housing and cover then the diff housing bottom
do not use paper towels, they create paper ***** that can plug up the bearings and other parts.
any 80w90 differential gear oil
add a limited slip friction modifier if you have the limited slip rear end with clutch pack
low cost store bottles are fine if no towing or heavy loads. 80w90 weight
Valvoline makes a good mid cost 75w90 that is part synthetic and has the limited slip additive already
Mobil 1 makes a top line 100% synthetic base oil 75w90 that has the limited slip additive
good for heavy towing apps.
do not use a 80w140, too thick for these diffs, too much power loss.
wipe the bottom of the diff housing out with a rag saturated with gas or acetone. removes the settled out fine metal cuttings and debris that sticks to the case. i use acetone, wipe the seal surfaces first on housing and cover then the diff housing bottom
do not use paper towels, they create paper ***** that can plug up the bearings and other parts.
Thread Starter
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Elder User
Joined: Apr 2005
Posts: 882
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From: Wichita
I noticed that the plastic diff cover has a small magnet bonded to it to pick up some of the metal filings. Be sure to wipe it clean too.
My diff has an electrical plug on the front near the top. I need to check my CD and see what is goes to. Any ideas?
My diff has an electrical plug on the front near the top. I need to check my CD and see what is goes to. Any ideas?
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Elder User
Joined: Apr 2005
Posts: 882
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From: Wichita
Originally Posted by copper_90680
That's the speed sensor.
For 2 nights now I've tried to get that fill plug out! I'm concerned about stripping the 3/8 socket. Last night I picked up some PB Blaster and decided to let it soak so we'll see if that works. My torch is in my garage attic storage and the pull down stairs are right above the Aero so I would need to push it out to get at it. What a comedy of errors!
I bought a new pipe plug with a 1/2" square "tip" instead of the crappy 3/8" socket in anticipation of getting the old one out someday.
Postmaster
Joined: Sep 2003
Posts: 4,452
Likes: 1
From: Southern California
Originally Posted by VanGo
Really? I thought they were on the trans. I can't find this plug on my CD