differential fill plug

[joshtypesn]

Today I tried to change the fluid in my diff. I could not get the fill plug out of the differential, with no luck I took to down to monroe muffler to see if they could get the bolt out. This was a bad idea as they returned to me and told me that the plug was ruined and would have to be drilled out. They said this was due to my first attempt (funny, because I'm not the one who used the impact wrench). Anyway, they told me they would have to remove it to get it out and that was the only option. Anyone else have a better idea to get the plug out with a now rounded out head? I have seen bold extractors but I cant seem to find one big enough. Also, any idea where to get a new plug? Thanks

 

[IZwack]

Ye ol' muffler shoppe ehh?

Well if its a muffler shop, they should have a MIG welder on hand and could have welded a large nut to it and then torqued on that nut.

Thats how I would do it.

 

[jlsparky7]

^ thats a good idea.

Or just use lots of heat, torch it for 5-10 minutes.

 

[budwich]

If heating it doesn't work (doubt it), then the "drill idea" is good.... since the "socket hole" in the plug acts as a center for the drill bit. Basically, you drill with a size smaller than the plug (eg. 3/8-1/2)... larger is better... because then rather than taking the plug out, you then just tap the "remains" for a "bolt of your choosing". This leaves you with a "filler hole" as usual, along with a way to still measure for proper level and plug the hole later. Others have just drilled an appropriate hole in the cover (at the "right" level) and plugged that. Either way is acceptable.

 

[IZwack]

The only worry I see with drilling is that it will push material into the differential housing. And its also difficult to get under there to drill because the gas tank is in the way. Welding is also difficult but welding only takes maybe a minute where as drill would take quite a bit longer.

 

[jlsparky7]

Just had an idea. Just buy a differential cover that has a fill plug on it. Ebay has some for under 30 bucks shipped and itll fix your problem.

 

[budwich]

The only worry I see with drilling is that it will push material into the differential housing. And its also difficult to get under there to drill because the gas tank is in the way. Welding is also difficult but welding only takes maybe a minute where as drill would take quite a bit longer.

Its not an issue (material).... you're taking the cover off to clean out the diff anyways. As for drilling, a right angle drill helps along with a short bit... but also jack up the body to get more clearance. Anyways, I done it on a couple of vehicles after struggling for "hours" trying every which way to get a bolt out. good luck though as any work like this is always "fun".

 

[joshtypesn]

jlsparky do you think you could direct me with a link to the part on ebay? I cant seem to find it. Thanks

 

[jlsparky7]

jlsparky do you think you could direct me with a link to the part on ebay? I cant seem to find it. Thanks

Im guessing its for a 8.8 rear? Ill try and find the link... I know there was one on there when I searched last week but ill look again...

No luck on ebay. All the ones with a fill bolt are $100 or more.

Heres a link for a cheaper one, check it out.

http://www.4wheelparts.com/Drivetra...Cover.aspx?t_c=12&t_s=237&t_pt=4041&t_pl=9286

Ill edit if I find more.

Heres a link to one with a rubber plug which would work fine. Only 18 bucks.

http://www.thepartsbin.com/catalog/?N=1616+10333+4294964191&Ntt=Differential Cover

If those aren't sufficient let me know and ill keep looking.