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Old 11-08-2005, 11:06 PM   #1
edjack
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Default Fill Plug corroded

'98 Legacy Outback, 84K miles. Want to change diff lube. Fill plug is corroded. Do I have to replace the diff cover, or is there an alternative?
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Old 11-09-2005, 11:10 AM   #2
Hayes
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Heck no. Just wire brush the plug clean and use some permatex sealer ( the ever soft kind) and you are good as new.
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Old 11-09-2005, 12:19 PM   #3
jac04
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Also, replacement fill plugs are cheap. I just bought one for about $2.75 from Jamie at subarugenuineparts.com.
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Old 11-09-2005, 11:13 PM   #4
edjack
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Sorry, I was not being clear: the plug refuses to come out. I have even tried heat (but maybe not hot enough).

I actually put a bottle jack on the breaker bar, and put a wrap in the bar, and left it there, while heating with a heat gun. Afraid to get out my Bernz-o-matic.
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Old 11-10-2005, 01:19 AM   #5
z
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Spray with some liquid wrench or something else that frees seized up nuts.

Then put a long piece of pipe over your wrench to get more leverage.
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Old 11-10-2005, 07:36 AM   #6
DrD
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do you know anyone with an impact wrench? If it's never been changed before, Subaru does put some sort of black threadlocker on there, so you need to break that free - shock loading usually works (like an impact gun, or if you put the breaker bar on there and try to load it like that)
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Old 11-10-2005, 12:43 PM   #7
Hayes
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Yes those suckers are tight because of the thread sealer. I used a 1/2 inch braker bar and a 2 foot length of pipe.
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Old 11-10-2005, 04:40 PM   #8
edjack
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Thanks for the inputs - I'll keep hammering at it. I began spraying Kroil on the plugs last night. I'll let you know what happens.
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Old 11-16-2005, 10:22 PM   #9
edjack
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Default Solved!

Took it to my mechanic, he put a breaker bar and a length of pipe on it, and got it loose, on the lift. There is no Loctite on the threads, as some have posited.

RedLine 75W90 installed. Good to go.
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Old 11-16-2005, 10:41 PM   #10
z
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Good to hear but, why did you pay someone else to do that when I said a few posts up to put a pipe over your wrench for leverage?
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Old 11-17-2005, 11:57 PM   #11
edjack
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zavigm,

I couldn't get it up in the air high enough to get a long enough lever arm on it. The mechanic said he had a LOOONG pipe on the end of the breaker bar, and he could do it because he put it on a lift.

The plugs were not Loctited in; just terribly tight, and with no signs of corrosion: the threads on the plugs were shiny, with no Loctite deposits.
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Old 11-18-2005, 05:03 PM   #12
DrD
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maybe the threadlocker is a more recent development - on my car it was on both the fill and drain plugs.
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Old 11-18-2005, 08:14 PM   #13
z
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edjack, at least he got it loose for ya. You should have no problem in the future getting it out if you decide to change it yourself later.


It's not loctite to keep the threads from backing off, though.
it's a liquid thread sealant that you should use so that gear oil doesn't leak out.
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