[rothjm]

My filler plug (don't know the proper part name) for the rear end is buggered up from the previous owner. I replaced the gasket on my rear differential. When I went to put in gear oil I found the plug rounded out. This is the recessed plug. I don't have an easy out that big. out:. I tried using a punch but I couldn't get it to budge.
I need some ideas on how to get the plug out. Thanks!

 

[bone z]

you could tack weld a short bolt in it to remove it and just buy a new one that would be the easy way

 

[Philip]

You could change the rear cover to the type with fill and drain plugs built in. Just do not fill it up to the level of the fill plug.

 

[airrj]

Jeff,

That is going to be a tough one to get out. The plug is a pipe plug, so it is a tapered thread that seats itself as the plugs gets larger as it goes in. So even if you did get a hole drilled in it and the proper sized EZ out (I prefer the square ones over the spiral type) you will likely need some serious heat from at least a MAPP gas torch and likely a Oxy/Acetylene torch. The breakaway torque needed to start turning a pipe plug is pretty high.

So, if you can get a rear cover with a fill plug, that would probably be the best option.

Good Luck.

 

[53Chev]

Had the same problem with mine last year. Rounded it out and yikes.....what a royal pain in the f*&%$$#%@@%[email protected]#$%@$#%@#$% ASS to remove. My mechanic had a simple solution: he welded a nut securely to the threaded portion and then heated it back up and smacked it with a hammer while turning it with a wrench. It came out seconds later.

He left the nut welded to it and it has worked ever since.

He didnt charge me anything for it either.

 

[Chris R]

The welded nut idea is the best by far. For good measure you have put a little heat from a torch to it to help it come out.

I have also had good success with using a chisel bit on an air hammer and by putting the bit in strategic spots, I was able to spin the plug off.

 

[michealdo]

there are tools out there that will take them out. I use them at work all the time. The part you are refering to is a Differential Plug. At your local parts store their should be a Differential Plug Extractor for a few bucks. Then you can install a new plug

 

[rothjm]

Thanks I will check for that tool.
I've been waiting for a buddy that has a welder to get a free eve.
Thanks for all your suggestions! You guys are great! :hurray:

 

[Lawson72]

Buggerd is one thing but mine was rustwelded together..it was a pain in the ass good thing i got steady hands...drilled a hole threw mine..then two small holes on top and bottom right by the threads....didn't damage anything..took a chisel and hammer and split mine out...then washed out the housing...put a new plug in...good ever since...was gonna go the route of buying a differ rear cover for my 12bolt...hard to find them with fill plugs in them and the ones i did i didn't like....find anything for a 8.5 10 bolt...but anyways thats my useless knowledge good luck....btw tried heating mine with a torch didn't have the first sign of moving...

 

[rothjm]

I got tired of waiting for the welder friend and went after with an easy-out. Got it out and picked up a replacement! Thanks all! :beers:

On to the next challenge and adventure!