Operation Lipstick on a Pig

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So, right when I'm hitting the home stretch, I rounded out the fill plug on the diff. Anyone got some ideas on how to remove it? I hit it with MAPP gas then the air chisel. It's really soft... FML, AGAIN!
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the one on my van is boogered too. I think someone took an impact gun to it at some point.
Anyways I fill it thru the vent tube now with a manual pump I picked up a HF for $10 or so.
 
the one on my van is boogered too. I think someone took an impact gun to it at some point.
Anyways I fill it thru the vent tube now with a manual pump I picked up a HF for $10 or so.
Ahhh, good idea, but how do you know when to stop? Dip stick in the vent hole....?
 
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with the van I know it takes almost 2 full quarts so I pump all I can out of the 2 quarts and between the 2 bottles there is appx 1/4 quart or less left. Unless I am mistaken I cannot recall putting in a full 2 quarts in a 7.5 either so same logic should apply. Surely the interweb should show what the typical capacity should be for a 7.5 rear.
 
Ahhh, good idea, but how do you know when to stop? Dip stick in the vent hole....?
I would just put a bottle in, then stick a 5mm Allen wrench in after. If you pull out any fluid on the wrench, you are good.
 
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I was thinking about wet hair hmmm
So, right when I'm hitting the home stretch, I rounded out the fill plug on the diff. Anyone got some ideas on how to remove it? I hit it with MAPP gas then the air chisel. It's really soft... FML, AGAIN!
View attachment 85483
Wow that housing just don't let up. I would finde something to hammer in the plug tight and heat the housing around it as evenly as possible once it's hot hammer on it again to decoil it and use stedy even pressure to remove it once you get it to crack free your home free. I don't think map gas is going to do it do you have a buddy with oxygen and acetylene torches? That's your best bet
 
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:popcorn: watching from a distance, waiting to see the pig come back to life....
 
if all else fails drill it .

put a fish tank net on the inside so the shavings fall into the net.

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