Trouble removing front differential fill plug

[OR VietVet]

Take the left hand thread removal bolt out. Smack the head with a big hammer. The force and vibes from the right amount of force will break loose the threads. I have used heat as well before ad that is my last resort. I normally use what I just described or, like Wade said, a nice dimple from a sharp punch/chisel blade and then keep smacking it in an unthread direction will do it as well and is typically my second attempt choice. If it has threads it will eventually turn out of there. It may bring some of the case threads with it though. Inspect the case threads and clean THOROUGHLY. On a component like that I like to just dab grease on the threads of the new plug and thread in.

 

[mooman]

Air hammer or electric hammer with a point. Dig it into the side closest to the threads and hammer away. I was in your same boat with s stuck drain plug and an Air hammer did the trick. The stock drain plugs are Magnesium and the housing is Aluminium. A very small amount of Anti-seize on the threads will greatly help you down the road. Make sure it is a very light coating on the threads closest to the head and not the bottom.
If you hear front diff noise, it is shot. if you have metal shavings, it is shot.

 

[torch]

Thanks for the thread info, saved me a bunch of headaches! Mine was seized, but I was in no rush, so every day for 3 weeks I sprayed PB Blaster on the plug. Then I used a 6pt socket and a std 1/2 inch ratchet, hit the ratchet handle with my foot, and it loosened right up.

 

[wjburken]

Thanks for the thread info, saved me a bunch of headaches! Mine was seized, but I was in no rush, so every day for 3 weeks I sprayed PB Blaster on the plug. Then I used a 6pt socket and a std 1/2 inch ratchet, hit the ratchet handle with my foot, and it loosened right up.

Glad to hear our experiences were able to help you avoid some frustration. That’s the great thing about this forum.

 

[OR VietVet]

Thanks for the thread info, saved me a bunch of headaches! Mine was seized, but I was in no rush, so every day for 3 weeks I sprayed PB Blaster on the plug. Then I used a 6pt socket and a std 1/2 inch ratchet, hit the ratchet handle with my foot, and it loosened right up.

Great outcome and thanks for posting your first post with a positive result.