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If you are servicing you rear end, be sure to pull the cover off to drain the old fluid. Clean out any crap in there, and the old RTV off the case and cover. While the cover is off you should be able to tell if you have the Trac-loc or not. If you have more that 50,000 miles on your rear end, it won't matter anyway because the clutch discs in the trac-loc are probably worn enough not to matter, so you won't need to add the Ford additive.
Put 1/4" bead of new RTV on the diff-cover and re install the bolts to 30 ft-lbs.
I would run 75-140 synthetic if I were you given your loading. It's pretty cheep insurance.
Yes, the bolt in the middle of the cover with the 3/8" socket head is the fill hole. Fill the diff until oil is to the bottom of that hole. Depending on your work environment you should be able to knock the whole thing out in about an hour.
the 3/8 square drive hole in the center is stripped out
if so the only way you will be able to remove it is to drill out the center of teh plug to relieve the tension on the threads and use a large easy out to remove it but you will get metal shavings in the diff so you may need to remove the carrier to remove all of it
most likely someone installed it with an impact , that is a no-no
I think I'm just going to leave the fill bolt alone and buy a rear diff cover that has a drain and fill hole already in it.
The only other thing I was thinking was to weld a 3/8 square drive onto the nut and then
try to remove it. But, it's not leaking now, and the rear diff cover is an easy, but expensive option.
You can grease the drill bit up good and it will catch allot of the drillings. Drill slow though.
Most likely stripped because somebody use a 3/8 ratchet and the ball that holds the socket kept it from going all the way and it rolled out of the plug. Pipe plugs are pretty soft.
I don't know why you guys are even discussing drilling the plug out installed. Risking metal shavings in the diff seems silly when the cover is so easy to pull.
I would pull the cover and try any of the good plug removal ideas suggested.
chewyjackson, what part of WA are you in? I have a spare 10.25 with a good cover that you can have if you need it. I would need your to replace it, but we could swap them in my drive way pretty quickly.
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