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Stubborn diff fill plug #5164662 07/18/19 08:21 PM
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HoosierJeeper Offline OP
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This is on my 05 Liberty's front diff. It's an aluminum diff, steel fill plug (just uses the drive end of a 3/8" ratchet). Just tried it with the vehicle dead cold (been sitting for a few days) and it seems pretty tight. Didn't want to force it. I'm thinking I should drive it and get it up to temp so that the aluminum expands (expands faster than steel I think?) and then that might allow it break free easier. Does that seem logical? Thanks!


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Re: Stubborn diff fill plug [Re: HoosierJeeper] #5164665 07/18/19 08:26 PM
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Maybe a little penetrant?
Then break that bad boy loose!

Good luck.


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Re: Stubborn diff fill plug [Re: HoosierJeeper] #5164667 07/18/19 08:27 PM
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Chris142 Offline
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Breaker bar.


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Re: Stubborn diff fill plug [Re: HoosierJeeper] #5164670 07/18/19 08:32 PM
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DukeOfFrontenac Offline
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Soak with penetrant, get it hot, breaker bar. Hit the latter half of the threads with never seize before re-install.

Re: Stubborn diff fill plug [Re: DukeOfFrontenac] #5164673 07/18/19 08:38 PM
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LotI Offline
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Originally Posted by DukeOfFrontenac
Soak with penetrant, get it hot, breaker bar. Hit the latter half of the threads with never seize before re-install.

Yup...for added effect before or after heating hit it with CRC Freeze-Off.


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Re: Stubborn diff fill plug [Re: HoosierJeeper] #5164732 07/18/19 09:33 PM
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In addition to penetrating fluid, tap the plug with a hammer repeated for a while -maybe half a minute or so. Don't beat the daylights out of it. Just firm taps. It goes a long way to break threads free. Works on brake fluid drain plugs too. Tap straight-on, not sideways.


Ray

Re: Stubborn diff fill plug [Re: HoosierJeeper] #5164743 07/18/19 09:48 PM
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HoosierJeeper Offline OP
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Sounds good. I just sprayed PB blaster on it so it can soak overnight then tomorrow I'll drive it and get it good and warmed up, give it a few taps as well. never had this happen before on it, although usually I do it warm.


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Re: Stubborn diff fill plug [Re: HoosierJeeper] #5164755 07/18/19 10:04 PM
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Iā€™d cross over with a 3/8ā€ x 1/2 inch adapter and use a 1/2ā€ ratchet. smile


If you want the job done right......do it yourself.
Re: Stubborn diff fill plug [Re: HoosierJeeper] #5164757 07/18/19 10:08 PM
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spasm3 Online Happy
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Can you get an air impact to it? I'd go low air pressure and let the impact hammer it a bit slowly.


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Re: Stubborn diff fill plug [Re: HoosierJeeper] #5164844 07/19/19 12:57 AM
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Impact as spasm3 suggested.


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Re: Stubborn diff fill plug [Re: clinebarger] #5164926 07/19/19 06:17 AM
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Egg_Head Offline
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Go to HF with 25% off coupon and invest in a breaker bar


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Re: Stubborn diff fill plug [Re: HoosierJeeper] #5164934 07/19/19 06:26 AM
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HoosierJeeper Offline OP
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I have a breaker bar and impact.... I was just afraid of putting too much force on it!


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Re: Stubborn diff fill plug [Re: HoosierJeeper] #5164935 07/19/19 06:26 AM
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Good reminder to teach the next generation: always remove the fill plug before dumping gear oil from a differential

Re: Stubborn diff fill plug [Re: HoosierJeeper] #5164994 07/19/19 07:34 AM
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Could always heat case around plug with a propane torch.


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Re: Stubborn diff fill plug [Re: HoosierJeeper] #5164998 07/19/19 07:35 AM
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Many a times factory torques don't match reality - they invariably very tight.
Few times stripped the transmission bolts as well and they don't come cheap ($10/piece).
Take it easy and lots of penetrating fluid.


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