Can't get the filler plug out of the rear end on my 90 f350 dually, can I use some heat? I sprayed but couldn't budge, afraid of rounding off in plug. Tapped etc. Doesn't look like ever out before.

 

Spray it liberally with liquid wrench or PB blaster, go in the house drink several beers then come out and try it.................Seriously, wait a couple of days after soaking it, then it should come out.

 

old93junk is giving good advice. thats simply what you got to do is spray it very liberally and then come back to it later if its really giving you a hard time.

 

Last resort, a friend did this on a Chevy..........Rounded out plug with ratchet, went to toolbox and found a HUGE torx drive socket (don't know the no.) drove the torx socket into the rounded out plug with a hammer, apply breaker bar, out comes plug......Never had to try heat.

 

Will try these tomorrow, thanks.

 

going along with these guys above, I would stick with the PB myself, its works better than most of the other junk out there and I would soak it liberally a couple of times a day if possable and let it soak! When i have a frozen nut or bolt I usually start soaking it 2-3 days in advance of when i want to work on that part. As far as using the heat on your case, I wouldnt reccoment that at all, maybe as an absolute last resort after everything else has failed, maybe... by heating up that gear oil inside the case your going to burn the fluid that is inside that case so your going to have to completly clean and flush all of the fluid in you axle, and to truely get it all clean is a real pain in the ***. plus on top of buring the fluid, remember that case is cast iron and you can weaken the case structure by heating it with a torch. so my advice is only after any and all other ideas are exhausted, then maybe u want to think about it. I hope that helps. when you do finally get that plug out i would reccoment chassing the threads on the case and getting a new plug, chances are its going to be kind mangled when i does come out from how you made it sound. that should be a 2-3 dollar plug you can get at any local hardware store.

 

if your going for heat, try a hair dryer or go for a good 15 minute drive and let it warm itself up, but I wouldn't recommend heating it very hot due to what yak3d has already said.

 

I would just go and get an ez out that fits the plug and crack it loose. After the liberal dose of spray. This is how i got my rounded out plug from my transfer case.

 

Have tried everything other than the ez out. Rounded off with largest torx, I'm afraid to drill for ez out will be getting metal in case, also I never have good luck with the ez outs, always break off. Any other suggestions?

 

Want to get it out heat it with a torch, its above the level of the gear oil to start with and the oil is what 90 weight to start with, "heat" is not going to hurt it.

Heat the housing around the plug, not the plug itself. If that doesn't work (usually does) then heat the plug and housing around it until red hot. Then the plug will turn, done it to several dif plugs over the years without a issue.
Your chance of gear damage is much higher driving it with very old, or low gear oil level then what heating it with a torch to remove the frozen plug will ever do to it.

While you're under there make sure the vent tube is clear.

Edit;

Oh and put a few wraps of thread tape or pipe dope on the new plug before you install it. No need to crank it down so tight to keep it from dripping that way and much easier to remove again later when needed. (It is "tapered" pipe thread).

 

td to close to the gas tank for me to go heating my rear end up.

if it did ignite, well see ya.

 

It is drained, will try again tomorrow probably heat it carefully.

 

If I tried to drill it and use a ez out how much metal would get inside and how would I remove it?

 

So far heat has not worked, I'm going to drill a hole try to jam a chisel in it and try to twist out, hopefully this works.

 

use a pipe wrench with a pipe attached if it is a plug like on the front of a ttb front end