Diff Filler Plug Stuck

[eXc]

Hey Guys,

I have a 94 Vitara I just bought. I have changed the front diff and gearbox oil, but I can't get the filler bolt out of the rear diff.

They are a stupidly shallow 3/8" drive hole. The guy before me has done it up stupidly tight and I can't get it to budge.

Does anyone have any tips for me? Should I try an impact wrench, or a rattle gun? Or will I need to weld something to the filler plug to get it out?

I can't believe Suzuki designed it with only about 3mm deep :S

Fortunately I was smart enough to try to get the filler plug out before I dumped the oil, so the car is still driveable.

Obviously I will get a new one. Don't suppose anyone knows a different car that has the same thread, but a 1/2" drive?

Cheers
Chris

[Mudsierra]

chisel and hammer? that did help for me on my rear diff filler plug

[=SKB=]

Weld a bolt to it. Heat will loosen it up as a bonus. Buy a new genuine filler plug. All done.

[Aerenandmel]

weld a short 3/8 socket extention in it, i had to do it the other day worked a treat.

[Gwagensteve]

I have had luck with a 1/2" to 3/8" adapter ground so it has nice sharp edges. (I did this by spinning it in a lathe and grinding it flat.) Most extensions and sockets have bevelled edges and these back the square drive out of the hole when you turn it.

I have also had to weld plenty of nuts onto filler plugs too.

Weld a good size nut on rather than a bolt, then the "modified" plug can stay on the car and you can use a spanner or ratchet to undo it.

PS - it is likely not due to the previous owner doing it up too tight - these tend to tighten in use. I never do mine up very tight and they are always a PITA to undo.

Steve.

[eXc]

ok thanks guys! I'll see how I go

[bazooked]

if ya stuff it up dont worry go to repco and buy another if they r the same plug as sierras, from memory they have a 20 mm thread go to repco and by a sump plug, comes with a nice big hex that u can use a 17mm spanner on.

[eXc]

Hey Guys,

I haven't had time to try yet, but what is the plug made of? What sort of welder/welding sticks do I need?

I have a 3/8 to 1/2 convertor I can weld on, but we only have a stick welder (but I have mates with MIGs if that helps)

I just don't know much about welding

Cheers
Chris

[jono_785]

mate u will be sweet with any old stick welder. i just welded an old wheel nut on there, chances are the heat will lossen it anyway so the weld will not need to be to strong. i struggled to find a new plug, my local repco said they didnt stock em, so i just ended up welding the nut properly on there. works a treat now. just impact wrench it off. lol

[bazooked]

ur ripco does stock them , u need to ask for a sump plug, they have the same thread, just got to tell em what size it is.

[lump_a_charcoal]

if ya stuff it up dont worry go to repco and buy another if they r the same plug as sierras, from memory they have a 20 mm thread go to repco and by a sump plug, comes with a nice big hex that u can use a 17mm spanner on.

That is a great tip!

[tommyk]

i had the same problem on my lux, if the plugs are the same style i have 2 suggestions. if the heads been rounded try getting the next size socket down, if it looks like its almost gonna fit, just hammer the socket on and try that, if that doesnt work try a hammerand cold chisel with a sharp face on it, start by making a chunk in the side of the head with the hammer and chisel, then tilt the chisel and start whacking it so that ur forcing the plug in the direction it loosens, worked for me. if anyone can understand what i mean, i cant explain well lol

[Dooley]

Mine had the same issues as well. The metal they're made of seems to a little soft.

Anyway, mine had a nut welded onto the back one from a previous owner, for the front, heated it up with with a gas torch.

Smelt like shit but it worked.

[Goldey]

Anyone had similar issues with the drain as well as the fill plugs? I have belted the crapper out of my fill plugs on both diffs, and they both refuse to loosen. Welding a bolt on seems to be the only answer....

[eXc]

Ok, I welded a bolt on last nite. No worries! Used a normal stick welder.

The heat ended up making it loose anyways, went to AutoPro and got a 20mm sump plug (has a 30mm head on it...shouldn't strip that sucker!) After I did the welding and the heat popped it out, dad goes "oh you shoulda just used the oxy to heat it then...." I didn't know he had an oxy.. haha grrrr

I also last week bought 2 new plugs from suzuki for the drain bolt, they cost me $10 each. next time I have the others out, I will put these in with a nut welded to them

[=SKB=]

Rather then weld a nut to a new plug, get some never seize and cover the threads with it. Locktite make it, costs around $10 I think. Save ripping nuts off on rocks (hehe) and ruining plug again.