I figured I'd share my experience with you guys just in case it might help somewhere down the road.
I tried to remove my rear diff fill plug (stock) and ran into trouble. It looked like it had been abused by a PO or lube shack in the past- corners rounded off and such. I couldn't get a socket to stay on it, so I went to the impact and rounded everything off. I then (calmly) got a cold chisel and began removing metal from the bolt. I was trying to turn it, but it was just breaking off chunks. I wasn't quite as calm by this time. I'd heard of someone having this problem who welded a bolt to the plug, so I got out the grinder, flattened the plug head, and welded a huge-headed bolt right on there. I went inside and surfed while it cooled, then I got my big six-point socket, wrench, and breaker bar, looking for a fight and ready to beat the crap out of it. I checked to see if the bolt was still hot (it wasn't), and then proceeded to turn it out by hand.
I had actually considered heating the housing before welding, but figured it wouldn't work. Sometimes I overlook the easy solution. I think a mapp gas torch would have made this job a lot easier- hopefully I can save someone some frustration with this story.
-Spike
I tried to remove my rear diff fill plug (stock) and ran into trouble. It looked like it had been abused by a PO or lube shack in the past- corners rounded off and such. I couldn't get a socket to stay on it, so I went to the impact and rounded everything off. I then (calmly) got a cold chisel and began removing metal from the bolt. I was trying to turn it, but it was just breaking off chunks. I wasn't quite as calm by this time. I'd heard of someone having this problem who welded a bolt to the plug, so I got out the grinder, flattened the plug head, and welded a huge-headed bolt right on there. I went inside and surfed while it cooled, then I got my big six-point socket, wrench, and breaker bar, looking for a fight and ready to beat the crap out of it. I checked to see if the bolt was still hot (it wasn't), and then proceeded to turn it out by hand.
I had actually considered heating the housing before welding, but figured it wouldn't work. Sometimes I overlook the easy solution. I think a mapp gas torch would have made this job a lot easier- hopefully I can save someone some frustration with this story.
-Spike