Rear diff fill plug is stripped and rusted?

[joesregalproject]

I've been doing some rear end work on the regal today, drums, shoes, and new rear diff fluid, and I've come to find that the 3/8 square fill plug (not one of GMs better ideas) on the rear diff is stripped. I haven't drained the fluid yet, so the car is still drive able, but how do I go about getting that plug out? A couple people have told me to weld in a bolt and turn it, except I don't have access to a welder. What do I do?

 

[pontiacgp]

I would get a cover with a filler hole or drill the old one out

 

[Hoopty_Mike]

Fill it from the vent hole, look around the differential and you will see a 1 inch plastic tube, that is the vent. Pull out the plastic tube and fill from there. I don't remember how much gear lube you need but someone else will. It's a PITA but it works.

 

[joesregalproject]

Any other ideas? This plug is really stuck, It's been soaking in penatrating fluid for a while now, so I'm sure it would turn, if only I could get a grip on it. Would a screw extractor work? If so, do I have to be careful when drilling, is there anything behind this plug?

 

[79loserbluebu]

http://www.gbodyparts.com/product_info. ... 68b3a9c943

 

[pontiacgp]

there is nothing behind the plug. If you remove the cover you'll see the plug. When I remove mine I use a 3/8 extension and give it a couple of good shots with a hammer.

 

[gwhiz]

heat ,heat,heat.get a propane torch and heat it up ,not just for a few seconds ,hold it there for a few minutes or so until almost glowing red.take you extension and pound it in and try to turn.If that dont work get it hot again and try a small chisel angeled in the direction to loosen it hit it with a hammera few times it should move if get a good "bite" on it,becareful the chisel could just shave off the metal and slip.if all else fails you could get a diff plug for a older chrysler rwd car,drill a hole and press the rubber plug in.

 

[tk76]

heat ,heat,heat.get a propane torch and heat it up ,not just for a few seconds ,hold it there for a few minutes or so until almost glowing red.take you extension and pound it in and try to turn.If that dont work get it hot again and try a small chisel angeled in the direction to loosen it hit it with a hammera few times it should move if get a good "bite" on it,becareful the chisel could just shave off the metal and slip.if all else fails you could get a diff plug for a older chrysler rwd car,drill a hole and press the rubber plug in.

Agreed !!! I have done this a few times always came out. Just go slow ! You can replace it with a male pipe plug from a hardware store.

 

[shanghaismith]

A new cover from RockAuto is under $15 +shipping
http://www.rockauto.com/catalog/x,carco ... ttype,2306

 

[shanghaismith]

....if all else fails you could get a diff plug for a older chrysler rwd car,drill a hole and press the rubber plug in.

Is that what is called a "butt plug"?