HELP!!!!!!!!!! Differential Fluid Change Problems!

[xxxchevelle69xxx]

i was taking advantage of the nice weather this weekend and changed my leaky rear end..........i put a new cover on and completely drained it, when i went to open the fill plug i couldnt get it open! it doesnt budge and a 3/8" extension does not work, i tried maybe going through the speed sensor but that bolt is frozen too, i sprayed them big time with PB and they still dont want to move, any advice would be wonderful i miss driving my baby

 

[JDraper]

More PB Blaster and let it soak or get a bigger cheater bar.

 

[Maniak]

Ditto on the cheater bar.. a 3/8" ratched didn't give me enough leverage. my 1/2" cheater bar with 3/8 adapter worked better (1/2 drive ratched still didn't give me enough leverage). I've even used an impact gun on it before (to take it off).. makes very short work of it..

~Mark

 

[JoeMahma]

i was taking advantage of the nice weather this weekend and changed my leaky rear end..........i put a new cover on and completely drained it, when i went to open the fill plug i couldnt get it open! it doesnt budge and a 3/8" extension does not work, i tried maybe going through the speed sensor but that bolt is frozen too, i sprayed them big time with PB and they still dont want to move, any advice would be wonderful i miss driving my baby

Try heating the plug a bit with a torch and spray Pb blaster on it to cool it down. The cooling tends to pull the blaster into the threads.

 

[parad1mg]

try to go the other way as in tighten the bolt a bit.. just to break it loose..

i just finished doing mine and the fill plug took some persuation to get off.. used a 1/2" breaker bar with a 3/8" adapter.. my neighbor was so amused tha he told me that i looked like i was participating in a tug-o-war contest and that the whole truck was swaying with me..

 

[techieman33]

Lots of pb blaster, that's also the reason it's suggested to make sure you can remove the fill plug before you drain the diff.

 

[budwich]

worse comes to worse.... drill it out ( from the out side). I had to do this with a GM. Then, i tapped the "left over" (drill out with a smaller bit to ensure that you are not touching the cast iron) to take a "normal bolt". Worked fine. As people have said, hit it with heat and spray...plus an impact wrench it a big help.

 

[Cobraguy]

Just make sure you don't screw up the housing or the plug. If you are in doubt, leave it! You should be able to figure out a way to install a fill hole in the cover. Use that to put in the correct amount of oil (won't be able to use the fill plug for a gauge any longer) and either take it to a shop to have it removed or figure out a way to measure the fluid level with the cover access hole. You can even buy covers with fill holes in them.

 

[xxxchevelle69xxx]

thanks for the tips guys, i was just going to head out and work on it when i discovered some brake fluid on the ground, my rear brake line broke so now i have that to worry about

 

[xxxchevelle69xxx]

just wanted to thank everyone for their tips again, i ended up drilling a hole in the cover and putting in a plug there, and i replaced the brake line so i can stop again, thanks again guys!