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Old 04-24-2004, 07:39 PM   #1
loudog800
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Default Differential fill plug stuck!!!

My differential fill plug is completely stuck (good thing I tried that one first). I tried all the tricks including using the jack to torque the wrench...nothing has worked. What are my options here???


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Old 04-24-2004, 07:45 PM   #2
Soon2Bgreat
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Give up...i gave up after a bit. I'm just taking it to a shop i think, not worth the trouble imo.
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Old 04-24-2004, 10:40 PM   #3
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Did you use a 1/2" drive breaker bar on it? This is the "proper" tool for it. Just slip the 1/2" square socket tip into the diff bolt "hole". If you can't get enough leverage with it, a pipe section slipped over the end should do it. The diff bolt IS a bear, so don't fear getting violent with it.
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Old 04-25-2004, 02:07 AM   #4
cnk
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Definitely use a pipe extension if you can't get it to break loose. I had to bench press the darn thing to get it to break loose. Just be careful of your fingers cause when it pops loose, you'll smash your fingers on the bottom of the car if you're not careful.

Calvin
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Old 04-25-2004, 02:20 AM   #5
AVATAR-X
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I have no idea how to get the damn thing off. I swear, we had a 2-foot bar on it and two of us were trying to turn it. We could push enough to start lifting the car but the bolt wouldn't budge.

If only we had a lift so we could push on the breaker-bar from a standing position instead of trying to get under the car and push up. We managed to get all our stuck lower strut bolts off (and those things must have taken more than 200 ft-lbs to get off) but the rear-diff plug won't budge.

One of these days, I swear, I'll get it.
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Old 04-25-2004, 02:23 AM   #6
esteve
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Here's what I did, and it was easy. With the car up on jackstands, lie on your back and put your feet on the bottom of the left rear tire with your knees bent. Have the breaker bar or ratchet facing the ground, grab hold, and use your legs to "pull" on the bar. Your legs and hips are much stronger than your upper body. It's like doing a leg press.
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Old 04-26-2004, 07:13 PM   #7
Tim Sanderson
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Use about a 1.5 foot 1/2" breaker and a large sledge. I think you will have better success with repeated hard bursts.

Good luck
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Old 04-26-2004, 08:29 PM   #8
Carnot
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Quote:
Originally posted by esteve
Here's what I did, and it was easy. With the car up on jackstands, lie on your back and put your feet on the bottom of the left rear tire with your knees bent. Have the breaker bar or ratchet facing the ground, grab hold, and use your legs to "pull" on the bar. Your legs and hips are much stronger than your upper body. It's like doing a leg press.
This method worked really well for me too. It's all in the hips.

-Bryce
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Old 04-27-2004, 10:17 AM   #9
Hayes
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I've seen an impact wrench used. Just make SURE it's set to loosen. CCW is the way to turn. I'm sure your are loosening it?? eddie
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Old 04-27-2004, 10:53 AM   #10
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1: Put car on trailer and tow onto an incline.
2: Open rear diff drain plug and drain fluid.
3: Tow car so it faces downhill (as sharp as possible).
4: Fill rear diff with fluid as much as possible (or factory recommended volume if possible).
5: Torque down drain plug back to 32.5 ft/lbs.

[Hey, i'm trying to be creative here...]

[maybe some sort of "tiltable lift" (if they even exist) could be used...]
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Old 04-27-2004, 12:14 PM   #11
Stanley
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I wound up taking mine to the shop after deforming the plug and ordering new ones. I tried an impact wrench with no luck. I watched the guy at the shop bust it loose and imho, it would have been almost impossible to do if the car were not on a lift. In the process of taking the fill plug out, it was mangled WAY beyond the point of being re-used.
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Old 04-27-2004, 06:13 PM   #12
RayO
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You gotta love how tight some of the bolts on our cars are.
I've done several "simple" installs where the biggest problem (and sometimes the show-stopper) was getting the factory fasteners off.
I did luck out on the drain plug, with the help of a three-foot pipe.
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Old 04-27-2004, 06:29 PM   #13
Karl
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Use a jack to push on the breaker bar up to loosen the plug.
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Old 09-03-2019, 09:52 PM   #14
pjineugeneor
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Here is what worked like a charm for me to get the fill plug loose on the rear differential of my vehicle . I have a 2000 GMC Sierra 1500 that developed a rear differential pinion seal leak. Mount breaker bar into fill plug hole and position handle so you can use a small hydraulic jack as other have suggested. Start jacking till you literally start lifting the back end of vehicle up.

Now for the magic part! I got into the bed of my truck right above the rear axle and launched all 230 pounds of me into the air and land hard. I could hear the fill plug 'crack' and sure enough, I was able to at that point use a ratchet wrench to remove the plug. Im sure a good hard bounce on the fender might have worked as well. Like an impact wrench, the sudden jerk (jump) was all that was needed to loosen the fill plug. Enjoy!
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Old 09-06-2019, 08:00 AM   #15
Mclemo
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These plugs are really hard to get off, the way I did it was using 2 people, one with a crowbar at the back of the housing mounting studs to keep the diff down, and a long 1/2" breaker bar. Even this method took a few shots, and started rounding the plug also. Just be careful, or use an impact wrench etc.
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Old 09-06-2019, 08:24 AM   #16
Bansheeboy11
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Jeeze no one knows how to loosen pipe threads these days lol, tighten the plug until you feel it "pop" and loosen, then it will come right out. If you need to, warm up the diff cover around the plug a little bit
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