Fill Plug is siezed... What would you do?

6BangBronk

6BangBronk

Well-Known Member
Joined
Jul 15, 2005
Location
Durham
Welp, got my 8.8 all buttoned up with everything I wanted to do to it and now I can't fill it due to the fill plug is seized. I tried soaking it for a few days and no go. Then tried heat and no go. Then I finally tried "all or nothing" and I stripped the square out where the extension goes into it. So I guess I need to either...

A. Fill it through the vent tube with correct amount of measured fluid. or...
B. Going to have to weld a nut to the fill plug to try to turn it. or...
C. Drill and tap another fill plug in another location. or...
D. Someone else's better idea?

What is thoughts on just filling through the vent and run with it? It's a trail/street beater Bronco if that matters. Nothing pretty and so far on the cheap side and would like to keep it that way... But not really looking forward to pulling the cover again regardless. Besides the fluid, this thing is 99% ready to drive all except some minimal wire clean-up along the frame rail.

Thanks!
 
Unbolt it, throw it away and go get another one.
 
XJsavage said:
Unbolt it, throw it away and go get another one.
Click to expand...

Throw away the entire axle? OK...

Just more info, the fill plug of this 8.8 is in the front housing, not the cover. Like almost 1/2" worth of thread surface mated. Axle was a tad rusty so my bad for not checking the plug before I even started. I did have other options...
 
RenegadeT said:
Welding a big nut on it should put enough heat in to break it free. Worked for me on a coolant port in a jeep 4.0l.
Click to expand...

This should work fine. Cool it with some penetrating oil. As it cools it should pull some into the threads.
 
if the 3/8" square is stripped out, i've used a pipe extractor(ez-out) of the appropriate size, if that doesn't work, a healthy size chisel may work to break the threads loose, privided there's enough of the plug exposed to get a bite on, both these will work as long as the plug isn't seized in the threads
 
A lot of excellent advice here but I will probably just fill from top and go on this one. If the sensor ain't stuck too.:flipoff2:

Thanks!!!
 
Myself, I'd weld a nut to it and do the wax thing. Sure you can fill in other locations, but, the fill plug is where you check the fluid level when you check ALL the fluids. once out clean up the housing threads, and the plug threads, put some anti-seize on it and re-install. next time it will come out easier and you can put a wrench or socket on it.
 
Seems the candle wax is unanimously the best way to go. Something I've never heard of and now am FORCED to try it just to satisfy my curious mind for the idea is so abstract/foreign to me. At first I was like "what the heck would candle wax do". :) I laughed at it until it got backed up...
But as for checking level, seems if one went a good splash over the measured minimum amount that it would blindly suffice especially since every aftermarket cover on the market has the fill hole like 2" above stock... Then if you see leakage, worry then...
 
Happened to me. I tried a lot things. Finally got it out with a square shank chisel that I ground down with a slight taper that I could drive in tight with a hammer then held in place with some blocks and a jack while turning with big wrench. Probably used some heat as well. I replaced plug with pipe nipple and pipe cap.
 
Welp, sensor was broke in half and the hole was plugged. Didn't want to mess fishing out all that so I went the bung and plug route.
 
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