Differential fill plug ---help please

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Aug 22, 2009 | 12:28 PM

Lotus76

Thread Starter

Pro

Joined: Mar 2004

Posts: 584

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From: Okemos MI

Differential fill plug ---help please

I am looking for suggestions for removing my differential fill plug.

For anyone that has done this you know how tight the space is to work. I can't get a wrench on it. I have removed this square plug in the past with a 12 point 5/8" socket.

Not this time! the corners of the square are rounded enough that I cant get enough torque on it before it slips off. This time its really really tight.

I also tried a crescent wrench from the over the top and used a ratchet extension (in the hole at the end) to turn the wrench but it wont budge (cant get much torque on it)

I used penetrating oil, vibration and heated the diff case, still no luck...

Does anyone have any creative suggestions to remove this square plug.

is there such a thing as a square socket? or a specialty tool that will work?

Sears makes a "gator grips universal socket" anyone had any luck with that?

Thanks for you help..

John

Last edited by Lotus76; Aug 22, 2009 at 06:42 PM. Reason: wrong socket size

Aug 22, 2009 | 12:40 PM

...Roger...

Race Director

Joined: May 2006

Posts: 16,528

Likes: 53

From: Dayton, Ohio

I use a square socket and a 10" extension with a 1/2" drive ratchet.

Aug 22, 2009 | 01:30 PM

KapsSA

Safety Car

Joined: Jun 2004

Posts: 4,358

Likes: 214

From: Beecher Illinois

A square socket is basically an 8pt socket. Try Sears. It's a 5/8".

Aug 22, 2009 | 02:07 PM

OMF

Melting Slicks

Joined: Jul 2006

Posts: 2,269

Likes: 480

From: Salmon Arm, BC

I hate to tell you this.....I tried all of the above recommendations with no luck. I ended up pulling the rearend - drilling out the plug breaking some easyouts - drilling the plug out some more and eventually using a hammer and chisel to break apart the remaining plug...what a PIA

I had to get a pipe tap to chase the hole after as some damage was done to the threads.
While I was in there I looked over my rearend and discovered some badly worn parts - that led to a partial rebuild.
This all started by me changing the pinion seal......so be prepared

Aug 22, 2009 | 02:26 PM

GTR1999

Tech Contributor

Joined: Aug 1999

Posts: 15,124

Likes: 3,927

From: Connecticut, USA

That plug is a 3/4" npt thread. Usually the 8 pt sockets work. If not hit it with a little propane and PB blaster and let it soak into the threads and try again. When I change the rear oil I just jack up the RH side on a small jack stand, slide under and remove the drain plug I installed, use the 5/8 socket and pump in fresh 80-145 Lucas.

Aug 22, 2009 | 03:04 PM