help: stripped diff plug
 

My differential fill plug head is stripped. I was going to JB Weld my allen head socket to get it out but does anyone have a better idea...? thanks

usually in that situation you have to drill it out

I am not sure about drilling it out. I would try soaking it with penetrating fluid, and then try heating the tranny case with a propane torch. Avoid heating the plug directly just apply heat to the threads.

And if those methods don't work, I'd probably next try an "EZ out". Its sort of a reverse thread tap. It bites into the thing you're trying to remove as you unscrew/counterclockwise the stuck part. You might have to drill through the plug itself to get this thing started, then crank away. Before I started all of this I'd apply liberal amounts of PB Blaster to the plug first to get it to let go a bit.

Thanks guys,

My hesitation with drilling is getting cuttings into diff case. Same reservation about using my EZ outs. I'll try heat, oil, JB Weld, prayer and then drill. Appreciate it.

Use an inside expanding bit. Looks like a large hex bit but has an offset section in the end that will rotate out and catch the inside of the striped out plug. Think these are made for plumbers. Got mine years ago for taking off the oil filler on VW's.

SoCal Driver,

Thanks. That's a great idea! Ironically I'm a building equipment engineer and have expanding bits. Just didn't think of using it on a car; must of had a senior minute

I believe the plug is steel. If the expansion bit you are going to try does not work and you have to do some drilling to get it out, you can always fish (troll) around inside the bottom of the tranny with a magnet to pick up the steel particles.

I'm a forced to retire mechanical designer/engineer ("It's the economy stupid").

I've always looked around to see if anything can be crossed over to the projects I've worked on. Tool applications especially for robotic end effectors. Of interest is that the 12 point bit needed for flywheel removal is the same as the 12 points in the hollow bolt that holds the two side mirror pieces together.

I guess "forced to retire" is better than "laid-off"

I'm not ready; keeping my fingers crossed my co. keeps it together

Was 3 1/2 years at a basic electrical design and drafting job till I asked why I didn't get a raise for the last three years.

The old fart that runs the four person shop took four days to contrive a reason to fire me.

The state unemployment didn't buy his excuse.

Still it's been a hard year with grabing every little contract design and drafting jopb that comes my way.

But I still have my 944!!!!

(Only because it's been paid for since 1987)

I can relate: through 4 jobs kept 3 constants: wife, house and hobby
car(s)
hope things look up for you; keep your 944

took a M10 bolt, reversed it and stuck bolt head into plug; spot-welded it there. Put 2 nuts on bolt. Using one nut as jam nut, rotated the whole works with a racheting box wrench.

Siphoned old gear oil out- nasty! Put in a new/old plug from Oklahoma Foreign.

why is it that the more expensive a gearbox or diff is, the bigger pain it is to get to plug?