So my weekend project was suppose to be an easy one. I planned on replacing the fluid in my rear differential sounded easy enough. I planned on removing the rear cover to allow it to drain and to redo the seal. Luckily I decided to pull the fill plug first. Yup you guessed it it is stuck in there good.

Things ive tried

1) hitting it with a torch and heating it up and allowing to cool several times.
2) wd40
3) pb blaster
4) a combination of 1, 2, 3 and a snap on impact
5) drinking some beer
6) drinking more beer
7) using a breaker bar with a 4 foot extension

any advice would be appreciated.

 

Never did get mine out. Had to refill rear end by putting a specific amount through the vent hose (long process). I would think that heat would be the answer. I didn't have it.

 

just in case how did you get it thru the vent hose just in case i do have to go that route.

 

yeah ive had to do that before

the way i always do it at work is wire wheel the heck out of it and knock all the rust off you can, stick a bolt into the square hole and weld it in there. let it cool for like 30 seconds then take it off and just buy a new plug or reuse that goofy thing if you dont really care

if you have to go the vent route just find out how much fluid you need and you just have to push it in there with a hose in those quart bottles or pour it verrrry slowly into it. if you have really bad luck that vent will be clogged too lol

 

Try heating it with the torch and then taking it out while its still hot instead of letting it cool first.

 

Don't heat the plug, heat around it.

 

I was thinking this but should have typed it as well to be articulate!

 

Paint half of your face with prussian blue and hit the corner of the square opening in the corner that backs the plug out shouting I AM William Wallace!

 

freedom!

 

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