Differential Fill Plug

[01sapphirebob]

So I was chamging the fluid in my differential and when it came time to fill the diff I ran into a problem. The "teeth" inside the fill plug had become stripped so when I went to loosen it my wrench moved but not the fill plug. I had to use a pair of channel lock pliers to get the fill plug out. However....now my fill plug is damaged to a point that I dont want to use it again. Has anyone gone with another solution? If I have to break down and get another OEM one I will but I knoe eventually it will happen again. Any ideas/suggestions would be great. Thanks!

[SA Heat]

When you say "teeth", do you mean the threads or the hole where the allen wrench fits into? If the plug is damaged and not the port, why not just get a new plug?....and why should it happen again?

[01sapphirebob]

When you say "teeth", do you mean the threads or the hole where the allen wrench fits into? If the plug is damaged and not the port, why not just get a new plug?....and why should it happen again?

The hole where the wrench goes. The current plug is almost like a plastic material and any amount of force will eventually strip the hole where the wrench goes. Taljed to my dealer today and the said the part is on national back order.

I wobder in a GEN V plug would work.

[ACtechOPS]

3/8 allen key fits very snug, goes in a long way - about 1/2", so slipping really shouldn't be an issue. Make sure you clean any crap out of the hole so you get full insertion. Plug is aluminum. Is it possible you used the wrong size key, an 11/32 maybe? That would grab, but much torque and it would slip. Only way I could see rounding out the drive hole. Think you need a new plug, Bob.

[01sapphirebob]

3/8 allen key fits very snug, goes in a long way - about 1/2", so slipping really shouldn't be an issue. Make sure you clean any crap out of the hole so you get full insertion. Plug is aluminum. Is it possible you used the wrong size key, an 11/32 maybe? That would grab, but much torque and it would slip. Only way I could see rounding out the drive hole. Think you need a new plug, Bob.

I need a new plug for sure. Problem is finding one now.

Here is the state of my current plug...

[SA Heat]

Other than the serrated "teeth" on the edge, what's wrong with it? It looks like the internal hex hole is fine. If the threads are okay, I'd clean up the edge with a file or bench grinder (just for the sake of cosmetics), throw some Teflon tape on the threads and thread it in....use the right size hex and torque to 15 lbs.

[Vprbite]

Call Jon B for a new one. You don't want to worry about that thing getting stuck on there.

[CarolinaViper]

If there's a next time, instead of using channel locks, which will slip and cause damage try a pair of vice grips. Less chance of slipping and causing damage to the outer edge. Looking at the allen head part, it definitely looks like the wrong size was used. If you don't have a set of allen head sockets get some, the leverage of socket wrench handle is so much better than a standard allen wrench.

[SA Heat]

If there's a next time, instead of using channel locks, which will slip and cause damage try a pair of vice grips. Less chance of slipping and causing damage to the outer edge. Looking at the allen head part, it definitely looks like the wrong size was used. If you don't have a set of allen head sockets get some, the leverage of socket wrench handle is so much better than a standard allen wrench.

I took the photo and blew it up and see what you're talking about with the hex damage. A new one is definitely in order....I agree with Vprbite, JonB can probably get a new one quickly.

[01sapphirebob]

I took the photo and blew it up and see what you're talking about with the hex damage. A new one is definitely in order....I agree with Vprbite, JonB can probably get a new one quickly.

Heres another shot of the fill plug.

[SA Heat]

^^^^
Ouch!