differential plug removal

[james accordino]

--- Peter Kirby <peterk at nrs.mcgill.ca> wrote:
> Even with using a Hazet 17 mm allen key socket, I
> managed to round out the
> socket head of my 90 Q's rear differential plug. 
> The metal of the plug is
> very soft from corrosion and seems to be thoroughly
> bonded to the aluminum
> casing of the diff.  Any suggestions as to how to
> either remove the plug
> (I've tried soaking it in penetrating oils,
> including ATF, tried knocking it
> counterclockwise with a cold chisel -- just rips it
> up)?
> 
> If I can't end up getting it out, what's the easiest
> way of checking/filling
> with oil -- remove half-shaft flange, remove
> diff-locking mechanism?
> 
> Lastly, any idea how hot a normal diff should get
> after about an hour of
> highway driving?  Mine gets sufficiently hot that I
> can touch it but can't
> keep my hand on it.  Does this sound normal?
> 
The same thing happened to BOTH plugs in the bottom of
my rear diff.  I employed all the same methods as you
with the same results.  I even used a torch on them
after pulling the diff. out.  I planned on removing it
to replace all the oil seals anyway, so I just drained
it through the fill hole.  Mine also gets about
equally hot.  I too wonder if that is "normal", or a
sign of bearing wear, increased gear mesh friction, ?

Jim Accordino