Anyone have a trick to remove a stripped fill plug? I recently converted to discs and drained all the gear oil. I know I can fill through the vent on the axle but that doesn’t seem like it’ll be fun.

I’ve seen a few people use extractor bolts and knock it loose by trying to turn the plug a bit with a chisel online but wanted to poll the audience.


72 cutlass 10 bolt
TIA

 

I have never seen one of these stripped on the socket side. Insert a 3/8 drive extension (without a socket on the extension) into the plug and extract.
If someone did however butcher the plug then a chisel may work to get it moving.

 

Filling through the vent is a huge pain.Try welding a nut to the plug.
Usually the heat from the welding will loosen the plug.

 

Welding a nut on is better, this worked for me, JB Weld a short extension into it and let it try overnight. Probably have to support the extension in place until it sets up.

Good luck!!!

 

we could help more if you post a picture. There may be a splined tool you could drive in if it has a square inset, or use a pipe wrench if it has a protruding square that is rounded off, Is it cast iron or steel? Welding the latter is possible, but cast iron is a different issue.

 

I welded a bolt in a plug on a 4wd transfer case. Worked great, you can put the threaded part of bolt in square of plug and weld.

 

If all fails you can fill through one of the axle tubes as long as you position it such that the gear oil will flow to the center section.

 

Pictures would be a better help. There are innies and outies ...Plug type.
I am assuming you have a 3/8 square innie. Sometimes if you catch if before the strip out happens you can just take a hammer and hit the plug flat making enough material fill the square area again and then tap the extension (3/8 square) into the plug and the hammer affect loosens the rust paint and debris form the threads. I always tighten the plug before trying to loosen it and that goes for just about any bolt nuts etc. If it has been torqued correctly it will always tighten a bit more that practice will prevent these issues too for future reference.
welding stuff onto the plug is always a very good way IF you have a welder. The heat will always help the stuck part remove easier.
chisel will help to to try and get it started.... any kind of heat helps... If the rear is in the car all these things can be difficult and trying.
MIGHT have to remove the rear to get a better handle on this problem....you also do not want to muck it up too much and make everything worse too.
Jim
JD Race

 

Thanks all. I got it last night. It took a chisel, but she’s out.

 

Great job. Glad to hear you do not have a huge mess. Happy 4th to you.