Rear Differential plug in sad shape

[96eb96]

Rear differential plug is corroded to the point where its jagged at the top. THe square drive barely goes in since the internal corrosion is preventing it.I tried cleaning it out with a screwdriver. I tried some PB and seafoam. I don't know if heat would be a good idea since the plug is so trashed also, I dont like using a torch under the truck so close to the gastank. I would probably have them do it on a lift if thats necessary. I'm worried when I turn the plug I am just deforming the square drive, so I am open for suggestions.

 

[IZwack]

Dont worry about that plug -- putting it there was a bad design from the start anyways.

If you cant get the plug off, buy a cover from JTsmith -- it'll have a plug in the back that will make filling the diff 10 times easier.

 

[96eb96]

Dont worry about that plug -- putting it there was a bad design from the start anyways.

If you cant get the plug off, buy a cover from JTsmith -- it'll have a plug in the back that will make filling the diff 10 times easier.

Wow...thats nice. I hate getting to that damn plug anyway. I will strongly consider that if I drop the fluid. My cover looks like its ready to crack from corrision. It is flaking apart.

 

[96eb96]

That drain plug looks very high up. I bet Lots of fluid is going to come out the vent.

 

[IZwack]

No the fill plug is at about the same location. Remember that the original fill plug is pretty high up on the front of the diff. Example (Maniak's cover):

 

[aldive]

It doesn't appear to have a drain plug/hole? Wonder why?

 

[96eb96]

Well I figured what the heck if it breaks I can get the cover. But I got the plug out. A few shots of PB, Dripped seafoam on it, but I believe the trick that got it was tightening it just a bit (about 1/10 turn) then when I reversed the ratchet there was little prevailing torque. It is a threaded plug afterall.

A guy installed that cover in another forum on a ford 8.8 and advised NOT to use the hole on the cover because it is too high. I looked at my diff and it is above my stock hole. If I get the cover I probably wouldn't trust that hole for a fill.

This link is also useful for anyone who wants to change their fluid ...

http://www.fullsizebronco.com/forum/showthread.php?t=115427

 

[IZwack]

Many off-roaders overfill their differentials all the time -- and some covers come with plug holes that are higher than stock. I know the 14-bolt is one such axle and the fill plug on RuffStuff Specialties' cover (which was originally very high) was moved down a fraction of an inch only because it caused a bit of interfere with a triangulated 4-link.

I guess we'll have to ask Maniak if he's had any problems with his cover.

 

[96eb96]

Many off-roaders overfill their differentials all the time -- and some covers come with plug holes that are higher than stock. I know the 14-bolt is one such axle and the fill plug on RuffStuff Specialties' cover (which was originally very high) was moved down a fraction of an inch only because it caused a bit of interfere with a triangulated 4-link.

I guess we'll have to ask Maniak if he's had any problems with his cover.

I probably know the answer, but you suggest Amsoil right? How about mobil 1 75W90? The book says 80W90 Dino. This is just a daily driver. I only care about synthetic for the potential gas mileage savings. Well, I want the gears to last long too.....

 

[IZwack]

I suggest whatever you can afford . But if $$ wasnt an issue, I'd go with Mobil 1 synthetic and the 75W will work fine, you live in Penpotawotnot anyway.

And dont worry about your gears lasting, they will last even if you use dino oil and the wrong weight. But whatever you choose, it wont give you any significant increase in MPG -- which is unfortunate .

 

[96eb96]

I suggest whatever you can afford . But if $$ wasnt an issue, I'd go with Mobil 1 synthetic and the 75W will work fine, you live in Penpotawotnot anyway.

And dont worry about your gears lasting, they will last even if you use dino oil and the wrong weight. But whatever you choose, it wont give you any significant increase in MPG -- which is unfortunate .

HahaHA...!!!!!! I thought I knew everything about the history of my area. At least I don't have to meet some Amsoil hillbilly with a shot gun! Thanks for the advice!

 

[gijoecam]

Well I figured what the heck if it breaks I can get the cover. But I got the plug out. A few shots of PB, Dripped seafoam on it, but I believe the trick that got it was tightening it just a bit (about 1/10 turn) then when I reversed the ratchet there was little prevailing torque. It is a threaded plug afterall.

Actually, the trick is a little bit of heat wrench. Using a propane torch, warm the housing a bit... the plug is sealed in place with some high-temp sealant/thread locker. The heat softens it and makes it easier to turn.

I always remove the fill plug before draining the diff. If, for some reason, it won't come out, I'm not stuck with an empty diff I can't refill.

-Joe