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Old 03-28-2008, 06:57 PM   #1
EJ20_lee
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Default my rear differential filler hole won't open

its all rusted and i tried to use breaker bars too but its not moving!!
do i have to change hole cover with sensor?
help me
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Old 03-28-2008, 07:17 PM   #2
rkramer
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use an impact wrench... I've seen bolts that would round out or break off when using a normal wrench, but the sudden shock from an impact wrench breaks the rust off instantly.
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Old 03-28-2008, 07:30 PM   #3
mikeythejew
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Spray PB blaster on it and wait 1/2 an hour and retry. Also try to tighten it 5 degrees and then loosen it.
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Old 03-28-2008, 08:55 PM   #4
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Try tightening it a little. Sometimes that allows it to break free. Also, might want to give it a little heat and use an impact gun. After that, remember when you reinstall the plugs, anti-seize is your friend.
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Old 03-28-2008, 10:15 PM   #5
nardvark
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It took me many applications of PB blaster, getting the rear wheels up on ramps, and putting my whole body weight onto the end of a 25" breaker bar to get mine to budge.

The car had ~70k and it hadn't ever been removed, so the factory sealant was stuck on pretty good.
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Old 03-28-2008, 10:40 PM   #6
p01ntb1ank
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i used a breaker bar and a floor jack on the breaker bar and it broke it loose
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Old 03-28-2008, 11:01 PM   #7
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Quote:
Originally Posted by p01ntb1ank View Post
i used a breaker bar and a floor jack on the breaker bar and it broke it loose
Yeppers....

Or a variant of the above...insert your breaker bar with the car on a jack. Release jack and let the car's weight do the work!
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Old 03-29-2008, 12:22 AM   #8
sigurd
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hit it with a hammer and brass punch around the outer edge before the impact.
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Old 03-31-2008, 08:59 PM   #9
EJ20_lee
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if i use impact! there is slight chance to break wholediff cover right?
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Old 03-31-2008, 09:13 PM   #10
Ryanr1490
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Heat around it untill its red hot, then use the impact. it will come out guarenteed.
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Old 03-31-2008, 10:52 PM   #11
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Quote:
Originally Posted by EJ20_lee View Post
if i use impact! there is slight chance to break wholediff cover right?
very, very, very unlikely - an impact wrench should make short work of it.
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Old 03-31-2008, 11:00 PM   #12
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Quote:
Originally Posted by EJ20_lee View Post
if i use impact! there is slight chance to break wholediff cover right?
an impact wrench will put ALOT less stress on the entire housing then doing it a slower way. (aka you have a higher chance of breaking the housing by using a jack or the car's weight)
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Old 04-01-2008, 03:20 AM   #13
specialev
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I had to use the breaker bar with all 4 feet of the jacks handle to get that damn thing off my 2002 WRX with 60k.
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Old 04-01-2008, 05:35 AM   #14
mopartodd
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Hey, I heard World Gym is running a special this week.

But seriously, just try the impact.
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Old 04-01-2008, 10:45 AM   #15
drivin blind
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Quote:
Originally Posted by p01ntb1ank View Post
i used a breaker bar and a floor jack on the breaker bar and it broke it loose
Only way I could get mine loose. Worked like a charm. I second the "anti-seize is your friend" comment. Last time I took it out without any problems. Also, don't take out the drain plug first. Fill plug first, then drain plug. RP
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Old 04-03-2008, 01:34 PM   #16
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Yeah, I changed my fluid at 30k miles and got it open no sweat with just a breaker bar. Then three weeks ago I tried to change it again, and couldn't get the drain open. We tried breaker bars and an impact wrench set to 120psi. No joy.
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Old 04-03-2008, 03:47 PM   #17
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We agree most have not seen negative effects by using an impact tool on it, but we highly recommend using the proper socket for those differential plugs with hand tools and a breaker bar. Our customers have found our KTC 13mm differential socket extremely helpful for those diff plugs as opposed to jamming a 1/2" drive end to remove both the filler plugs and the drain plugs.

I understand the OP was specific in having trouble with the filler hole on an STI which has the temp sensor, but strangely we have sold to STI customers who for some reason have no sensor there, just a standard square plug, probably due to second hand vehicle purchase mishaps, so I thought this info would be valuable.





www.ultimatetoolco.com
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