differential plug removal

[David Glubrecht]

Here is another use for your handy-dandy wire feed welder.  On one of these
that I found that was both siezed and stripped, I welded a large nut to the
plug (weld on the inside, thredded part of the nut).  I was a bit concerned
that the weld might not be strong enough and just break off, but the heating
also unseized the plug.  It was able to be removed with very little force
once the nut was welded on.
    Dave G





> 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?
>
> Thanks.
>
> Peter
>
>