Front Differential Fill Plug Removal?

[EddieC]

On a few attempts at removing the plug it seems pretty well stuck.
I have seen pictures of replacement plugs and the head seems to overlap the opening of the case so it seems penetrating fluid probably will not get past the seal under the head to get to the threads.
Is there a means to get it out without screwing it up and never getting it out?

 

[Doubeleive]

On a few attempts at removing the plug it seems pretty well stuck.
I have seen pictures of replacement plugs and the head seems to overlap the opening of the case so it seems penetrating fluid probably will not get past the seal under the head to get to the threads.
Is there a means to get it out without screwing it up and never getting it out?

I believe it is just a 3/8" socket hole, I just did mine a month ago, I put a socket extension on my ratchet, wouldn't break loose so I used a breaker bar over the ratchet and it broke loose just needed a little more leverage

 

[rdezs]

The socket hole is the drain plug. You always want to make sure you can get the fill plug out before draining.... The fill plugs can be difficult.

Yes, the flange of the fill plug overlaps the case with a built-in o-ring of sorts. Pick up a new one before you get started. I always keep one on the shelf. The "bolt head"... Can't remember but I think it's an 18 mm?.... Well the bolt head doesn't protrude much, and actually appears somewhat tapered. A good 6 point box end wrench and a few taps with a hammer often works. A little heat around the plug helps as well, but don't overdo it.

In the event the bolt head gets rounded off, which is not uncommon, a cheap harbor freight socket and a few spot welds with a MIG welder to the bolt head always does the trick. If you don't have access to a welder, any local shop can do it in just a couple minutes for a nominal fee.

I always use anti-seize when putting the new fill plug in. And follow the torque spec, as you don't want to over tighten it.