Help Me Get This Diff Cover Off

tlucier

tlucier

Well-Known Member
Joined
Jun 3, 2007
Location
Mebane, NC
I thought I'd take advantage of the nice weather today and change my diff fluids. Front diff was no problem. Rear diff - different story. Its an 8.8 in my '01 TJ. I've got all but 4 of the flat head socket cap screws loosened. So far I've broken a Craftsman 3/16 hex bit, a Kobalt 3/16 hex bit, and my 3/16 allen wrench just flexes - the bolts ain't moving.
So does anyone have any ideas to help me get the last 4 bolts out so I can finish this job without trashing anymore hex bits? Thanks in advance for your help. :beer:
Broken Craftsman is on the left, broken Kobalt is on the right...
ai209.photobucket.com_albums_bb284_tlucier_16Jan0_20__20Rear_20Diff_20Cover_20Removal_Pic002.jpg

The 4 bolts that are kicking my butt. They are at the top of the cover.
ai209.photobucket.com_albums_bb284_tlucier_16Jan0_20__20Rear_20Diff_20Cover_20Removal_StuckBolts.jpg
 
GotWood said:
impact wrench or heat?
Click to expand...

Maybe heat would work. I'll give it a try tomorrow. I wuld think an impact wrench would snap the hex bit. Heck, if I can snap the bit by hand with a standard 3/8" ratcher, wouldn't the impact wrench just torque the hex bit to pieces?
 
Cool pic of the broken hex bits. The Craftsman broke in a more brittle manner, which means it was hardened deeper. The Kobalt had more of a case hardening, but probably twisted a little before it broke. Were you using a bigger ratchet or breaker bar with the Kobalt?

It will be very challenging to get the bolts out with allen heads. You may end up needing to just drill them out and then thread the remainder out with vise grips. If you use a drill bit as large as or larger than the threads of the bolt, you should have em all off in 5 or 10 minutes, just be patient so you don't break any bits.
 
braxton357 said:
Not necessarily. Have you tried vice grips or putting the other bolts back in and taking those 4 out?
Click to expand...

The heads are recessed in the diff cover so I can't grip the head with vice grips. I haven't taken out the other bolts, just loosened them by 1/2 to 1 turn.

Think I should tighten them back down and try to loosen the 4 that are stuck? Guess it's worth a shot.
 
jeepinmatt said:
Cool pic of the broken hex bits. The Craftsman broke in a more brittle manner, which means it was hardened deeper. The Kobalt had more of a case hardening, but probably twisted a little before it broke. Were you using a bigger ratchet or breaker bar with the Kobalt?

It will be very challenging to get the bolts out with allen heads. You may end up needing to just drill them out and then thread the remainder out with vise grips. If you use a drill bit as large as or larger than the threads of the bolt, you should have em all off in 5 or 10 minutes, just be patient so you don't break any bits.
Click to expand...

Hey Matt - Used the same ratchet on the Kobalt as on the Craftsman. No breaker bar was used. Looks like I'll be doing some drilling tomorrow to get the heads off. Hope the remainder of the bolts come out somewhat easy.
 
Take a small pin punch ( small enough to fit inside the hex to the bottom) and a hammer, smack each bolt a few times. even using the hex allen would help.

using an impact driver with the proper bit on it would work as well.

when you reinstall, apply anti seize to the cone and threads of the bolts.
 
Thanks to everyone that replied. I'll try what y'all suggested and worse come to worse, I'll drill off the heads and get some new bolts.

Blkvoodoo - thanks for the tip on the anti seize. Once I get the rear diff squared away I'm going back to the front diff and hitting those bolts with anti seize as well. Nice tip!
 
can be had for same or less at any auto parts store as well.
 
I would go with heat and impact driver. At least it's where you can use alot of heat with out damaging internal parts.
 
Props to all of you guys that posted trying to help me. :beer:

This morning I went to Lowes and got my money back for those cheesey Kobalt hex bits. Would you like to exchange these for a new set? Hell no. Off to Sears, exchanged the broken Craftsman bit with a new one and bought another one just in case. Got back to my garage, took a punch and a bmf hammer and whacked the hell out of those bolts. A bit of gentle pressure with the new hex bit in my ratchet and they came right out.

You guys are awesome. Thanks for the help!
 
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