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  1. #1
    74Fjord02
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    Stuck Diff Fill Plug - Not Good!

    Okay, I've done the ultimate in stupid. I've accepted that part, but still need help.

    I drained the diff fluid before losening the fill plug...and of course, the fill plug internal hex is stripped out. Yes, the 10mm internal hex is completely stripped. God knows why the PO replaced a plug in that condition, but that isn't the point.

    I first tried the 10mm internal hex and it wouldn't grab at all. Then I tried a bolt extractor in the roughed up hex hole which didn't work either. Then drilled a 15/32" hole to the depth of the internal hex, without going through plug. Then tried the extractor again and the plug still wouldn't come free. Now there is a pretty round hole in the plug and a stuck fill plug...

    Options I can think of -
    1. cut two flats on the stuck plug for channel lock or wrench
    2. Put a 10 mm hex into 15/32" hole and weld in the hex, which doesn't seem smart at all
    3. attack it with a cold chisel and hope for the best
    4. your ideas here

    Please help!

    TIA, grounded 74Fjord02


  2. #2
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    No. 1 first, No.3 last try.


  3. #3
    Arizona 02
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    apply heat w/ torch to diff area around plug

    Last option most time consuming is remove diff & fill thru drain hole.

  4. #4
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    Re: apply heat w/ torch to diff area around plug

    Any idea if the rear diff cover can be removed without removing the entire diff?

  5. #5
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    Member No: 120934 meyere30 is on a distinguished road meyere30's Avatar
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    Its a PIA. Drill a hole all the way through.

    heat it and you an easy out to remove it.

  6. #6
    74Fjord02
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    More thoughts on stuck diff plug...

    Thanks to everyone for the insight and thoughts.

    After looking into this a bit more, here is what I am thinking:

    1. Get #5 Reverse Thread Extractor and cut enough off of the taper end to get a good bite on the 15/32 hole in the plug. See if that works.

    2. If not, remove the diff rear cover in situ. This also sets me up perfect for new diff bushings which are needed anyway. Once the cover is removed there are many ways to get it out.

    BTW, new fill/drain plug ($9.50) and crush washer ($0.55) from BMW. Not the end of the world, just a PITA!

    Rob

  7. #7
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    Hope it comes out the easy way.


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