extracting stripped fill plug

orange150

orange150

Well-Known Member
Joined
Mar 20, 2005
Location
Fairfax City, VA
anyone got any ideas on the best way to extract a stripped fill plug out of my rear end? the PO must have not used the right tool or something, now the part that the 1/2" drive goes into is more round than square. I would just fill through the speed sensor but that got stripped out by stupid Ford Techs. Only other idea is to buy a diff cover with a fill plug in it. I do need to get to it because I blew a seal out and there is no diff fluid in it.

One thought is to weld or JB weld a bolt head to the plug but that could potentially screw me up big time.
 
Bolt welded into the plug would be my first thought, aside from that, a large easy out, or drain it, drill it out, tap it and install a larger plug.
 
I'd clean it up good, find a bolt that will fit inside it, and weld it to the plug. Then all you will need is another plug.
 
Finish rounding the hole ( drill ). Cut a bolt to fit and weld it to the plug( depth and width).
Once it's out weld it good and you'll have a usable plug again.


Matt
 
Can you take the dif cover off and get a grip on the inside with vice grips?

OR geet it out with a chisel as suggested or weld and remove and replace fill plug.

I guess depending on vehicle maybe the plug isnt in the diff cover?
If its in the idff cover just take diff cover off and work it out.
 
the chisel/hammer trick didn't work either.
This is how i fixed my problem, cost about $2.50 in parts


do i need to brag about my sweet welds?:flipoff2:
 
no, the original fill plug is on the diff itself. that is an 02 sensor insert with a plug i found at the parts store. just cut a hole in the cover and welded it up. I made it way above the original fill plug incase I get any leaks from my awesome weld job.
 
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