Differential Difficulty

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Mar 25, 2002 | 12:23 PM

jaysonb

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Joined: Feb 2002

Posts: 145

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From: Los Alamos, NM

Differential Difficulty

I have a '81 F-150 4x4. I went to check/service the rear diff (9")and couldn't....
The fill plug is the type that takes a 1/2" ratchet inserted into it to turn it, but, about a third of the 'shoulder' of the plug is broken off and I could not get it to turn. Anyone else ever have to deal with this? any suggestions?
Thanks in advance for any input.
Jayson

Mar 25, 2002 | 12:41 PM

redranger1

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Joined: Dec 2001

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From: Iberia, USA

Differential Difficulty

i would drill a hole in the middle of the plug and use an easy out to remove it.

-nathan

Mar 25, 2002 | 02:31 PM

jaysonb

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Joined: Feb 2002

Posts: 145

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From: Los Alamos, NM

Differential Difficulty

I thought an easy-out might work, too, just a little scared to run a drill in there...
Thanks,
Jayson

Mar 25, 2002 | 03:07 PM

Wilber15

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Joined: Nov 2001

Posts: 892

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From: Duluth, MN

Differential Difficulty

It'll be fine to drill on it, as long as u don't ram it through the other side. Then use the easy out like stated above.

Mar 27, 2002 | 12:52 PM

Art

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Joined: Jul 1999

Posts: 472

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From: USA

Differential Difficulty

BEFORE DRILLING ANY HOLES, I suggest taking a 3/4" to 1" dia punch (same dia. as OD of plug) and a 2-3lb hammer to the head of the plug. Hit the plug as if trying to push it straight into the differential. The shock from the sharp blows will loosen the threads - the plug is NPT which relies on thread interference for sealing.

This trick works extremely well on O-ring plugs too!

Art
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Mar 27, 2002 | 01:14 PM

AZ4x4f150

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Joined: Jul 2001

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From: Glendale USA

Differential Difficulty

[updated:LAST EDITED ON 27-Mar-02 AT 02:16 PM (EST)]if it is a 9" rear end take the third member out before drilling it will be easier with the third member on a bench or on the ground not that much oil is going to come out because well you loosened the axles some will come out there instead and with the third member out you will know there aren't any metal shavings from drilling on the inside or the housing and then when you have it out you can drill the housing near the bottom and install a drain plug near the bottom which you can buy a plug kit for about $10.00 from napa and in the future you won't have to mess with taking out the third member anymore to change the gear lube