Outer Limits 4x4 Board

Well changed the oil in the diffs, transfer and gearbox yesterday.

But just thought I'd bring this up. Has anyone else had problems with the diff fill plug seizing up and being a pain in the ass to get off ?

When me and my mate were doing the front diff fill plug we first tried a normal socket set, then we tried a longer bar, then we tried the longer bar and tapping it with a hammer, then we tried an impact driver. Finally we had to use a gas torch to heat it up. Smelt like shit, but was one of only two options we could think of. The other was what had been done on the back diff fill plug. A long nut had been welded onto it. Unfortunately welding a nut onto would have been a pain and we also didn't happen to have a long enough nut anyway.

So the front ones been chewed up a bit. So getting on with the whole point of this post. Any solution to this ?

I'm probably going to be getting a new/used plug as its not too flash now, but is there a point really if its gonna do the same thing.

I had the same problem a while back too, in the end I stuffed the plug completed. just happened to have a spare Valiant AP 5 plug which was a perfect fit and was a bigger nut size. So if you happen to have a spare one of those then you're in luck

i normally use a smear of ultra gray on the plug when i put it in (filler that is) saves it from rusting in place.

Or try and get an allen key style plug.

I get about a meter of some kind of tube and use it as a big breaker bar. Ive never had to heat it up.
(the plug on my front diff is pretty ordinary)

I swapped the fill plugs from a 410. They have a male rather than that female that required punching to get out.

cold chisel works for me.
no-one admires a nice oil filler bolt!!!! do they?
so why worry.

enjoy ashley

no-one admires a nice oil filler bolt!!!! do they?
so why worry.

Not the looks I'm worried about. Just want to make sure it doesn't seize up again. Plus the square hole is now more like a rhombus. So don't want to do it up as tight as I can only to make the hole into a circle trying to get it off.

So yeah, was just looking for any solutions.

The previous owner or owners of mine had rounded out my filler caps,
which made me think when was the last time the oil had been changed?
i ordered some new ones and got out the trusty cold chisel.
i got told from the guy i got the new ones from, that it is a common problem(seizing and rounding out ) because of the poor metals(cheap) used in the plugs. I couldnt get any good ones from the wreckers as they were all the same.

Chop

I have that problem in my rear, but it is that bad i actualy carnt get the plug out it is sezed that bad. the last time i changed oils i used a break like sucker and sucked it all out.... but i think it might be a job for the drill and easy out this time

Red_Zook wrote:I have that problem in my rear, but it is that bad i actualy carnt get the plug out it is sezed that bad. the last time i changed oils i used a break like sucker and sucked it all out.... but i think it might be a job for the drill and easy out this time

erm .. I think that you may be on the wrong forum posting that kind of stuff .. you should use an antisieze type lube when you put a plug in your rear ... or so I am told

on a more seriious not and not talking about butt plugs .. I found that
1. Impact driver was useless as it simply made the area around the pug get pushed inward
cold chisel .. almost as bad .. but eventually got it out

when changing the oil in my lil bro's zuk, the fill plugs were not moving either .. a 30 sec to a min with the propane torch and they came out very easily.. when reinstalled a bit of never sieze on the threads .. we will see in 6 months time if it worked ..

there is a special tool that your mechanic may have to remove the diff plug. completely rooted mine, when i got the tool (think is a 6 sided snapon or someting) came out easy peezy. if you root the plug they are onlt $5 for a brand new one!

Intend doing mine properly today. Have previously used the diff oil breather hose to fill both my diffs through the breather hoses but is a PITA and take for ages. Intend to cold chisel mine to break the rusty seal that has formed then take it down to the local auto spares shop to compare what else is on offer. I really would like to use a male hex plug but will let you know what I find. Don't like the noise my rear diff is making again. Ohno not another diff broken ?

I ended up giving up. The bloody diff filler plug looks like it's case hardened and a very sharp cold chisel just bounced off it a lot blunter. Checked my oil for discolouration or water and it looked fine so I guess I'll just revert back to filling my diffs through the breather connection.

If you have a welder handy, just weld a largish nut onto the rounded out filler plug and try to undo it. Have dont this before, and worked fine.
Layto.....