stripped Diff (fill) bolt (1 Viewer)

[Tuning Haus]

haha hey thanks guys for the inputs!

i tried to use my welder and as i was ready to get under the truck, the machine quit working!

so i'm going to have to try heating the bolt up (haven't tried that yet). one of those propane torches would work well? i'm afraid the under side of my car is filled with grease and oil that i might catch things on fire... lol

i haven't tried a pipe wrench! i never thought it would have enough grip!?!?! if a vice grip didn't have enough grip, i don't see how a pipe wrench is going to grab onto this with enough leverage... especially if it's rounded already... but i'll give it a shot anyway...

i'll try that and if it doesn't work, i'll heat it up and pipe wrench or vice grip it off... and if that doens't work, i'll try to weld a lug nut on the end of the fill bolt (if i can fix the welder).
if THAT doesn't work... then i'll fly snow wolf out to get her done!

 

[Beowulf]

Always use a 6pt 24mm socket on the drain and fill plugs. My preference is to convert them to the 10mm allen head as shown above. Cruiserdan can get you a set of those plugs.

See if you can pound on the 24mm socket. If not, then use a chisel. Give the head of the plug a good whack or two with a BFH before you start.

The last resort for me would be welding a bolt.

-B-

 

[WarDamnEagle]

i haven't tried a pipe wrench! i never thought it would have enough grip!?!?! if a vice grip didn't have enough grip, i don't see how a pipe wrench is going to grab onto this with enough leverage... especially if it's rounded already... but i'll give it a shot anyway...

Pipe wrenches are made to grip round objects....and they grip round objects much much better than vice grips.

 

[jlbuk]

One of my trucks has a rounded off fill plug on the rear diff... I've always wondered what I coudl replace it with when I get it off, as I can;t see the point of putting the same (replacement) shallow head bolt back on - why didn't they make the head deeper ? On the drain I understand, but not the fill...

I like those camry hex bolt flush fit ones, much better...

 

[cptmud]

cold chisel and hammer works a treat.

 

[Tuning Haus]

guys, thanks for all your inputs and ideas.

i tried everything everyone said on here and even had two mechanics come over to look at it and help.

it almost SEEMS welded on there... it's ridiculous...

i heated around the bolt as well with a propane torch a few times... wd40'd it a TON and still no avail...

i ended up getting a drill and drilled through the middle and am going to attempt to extract it.

we'll see how that goes...

 

[bpassmore]

be sure to flush that axle before driving on it....

 

[wxm]

haha hey thanks guys for the inputs!

i tried to use my welder and as i was ready to get under the truck, the machine quit working!

so i'm going to have to try heating the bolt up (haven't tried that yet). one of those propane torches would work well? i'm afraid the under side of my car is filled with grease and oil that i might catch things on fire... lol

i haven't tried a pipe wrench! i never thought it would have enough grip!?!?! if a vice grip didn't have enough grip, i don't see how a pipe wrench is going to grab onto this with enough leverage... especially if it's rounded already... but i'll give it a shot anyway...

i'll try that and if it doesn't work, i'll heat it up and pipe wrench or vice grip it off... and if that doens't work, i'll try to weld a lug nut on the end of the fill bolt (if i can fix the welder).
if THAT doesn't work... then i'll fly snow wolf out to get her done!

You would be surprise how effective the pipe wrenches are for these kind of application. Unlike the vise, the grip increases along with the torque. (make sure you use it in correct direction).

 

[Tuning Haus]

You would be surprise how effective the pipe wrenches are for these kind of application. Unlike the vise, the grip increases along with the torque. (make sure you use it in correct direction).

thanks... yep i used a pipe wrench and it was no good... i did make sure i used it on the right side and that was one of the problem. on the diff housing, one side sticks out and the room i had to work with didn't allow the wrench to get a good grip on the bolt at all... not even close
i can see if you had a lot of room and maybe for a bigger piece.. but this bolt is already mangled and it doesn't stick out far enough to get any grip...



i'll be sure to flush the system again before i drive it (IF) i drive it..

 

[bpassmore]

pics please....

 

[greenfox]

pics please....

here you go

 

[arndog123]

LOL.

 

[ELW2]

The suggestion to replace the OEM fill plugs with Camry 10mm allen head plugs is excellent.

My rear differential fill plug looks like it's rusted in place.

Unfortunately, I rounded the bolt head yesterday.

Soaked it in PB Blaster and will try again today.

This may help remove rounded fill plugs:

BEXW301, Extractor, Hex Head Fastener, 15/16" (24mm), 1/2" square drive

 

[IdahoDoug]

So, what happened with the original poster on this? Get the fill plug off? It's been 3 weeks.

ELW - don't be afraid to use a hammer and chisel. You can generate enormous force with a few well placed hammer blows. I used a 4 point socket with cheater bar being pried on with a floor jack by a friend. Left me to use a piece of wood to apply extreme pressure to keep the socket shoved on while the prying popped it loose. Worked no problem and I'd guess the force to crack it loose had to be well over 200 ft-lbs. Was a friend's 80.

DougM

 

[john_eckels]

The Hammer and Chisel worked well for me. For future reference, I purchased a 15/16 socket and ground the end down so there was no bevel. With the bevel, you lose about 1/8" or half of your gripping power on the bolt head.

 

[Beowulf]

So, what happened with the original poster on this? Get the fill plug off? It's been 3 weeks.

Uhhhh Doug, it has been over a year. The OP started this thread in Jan, 2009.

-B-

 

[KimoSabe]

PO of my 94 LC must have stripped/rounded the diff bolt-head over torquing it on, leaving me with the headache, thanks to this thread, gave me a few options.

First option - chisel's a great idea - https://forum.ih8mud.com/images/smilies/idea.gif .... for future info, I attached a pic of the conquered bolt. Used an impact gun/wrench with the chisel. Took 14 seconds.

 

[NerdNoise]

Weld another bolt to the diff fill plug bolt and then turn the new bolt. Also, spray lots of PB or your favorite penetrant and soak for a nice long while.

You might be able to drill it out if you are careful.

Good luck.
-o-

Welding on a nut worked for me. Three things saved my can: 1. I did not drain fluid first. 2. The heat from the welder loosens things on the threads. 3. the 1/2" nut on there is freakn' awesome. No need to replace the plug. Just leave that one on there and it works great. I did it to the other two just because.

 

[matt32]

I hope you did not remove the drain plug first....

I just did a birf replacement after driving around for a little while in 2wd but forgot to drain the diff before hand. Now I am all done except refilling my diff and have a rounded off fill plug. Why must I pull the drain plug first?