differential plug removal

[Fred Munro]

Hi Peter;

You might be able to drain it using a suction gun and flex tubing through
the fill hole. You won't get the filings off the bottom, though.

Fred Munro
'94 S4

----- Original Message -----
From: "Peter Kirby" <peterk at nrs.mcgill.ca>
To: "Audi list" <audi20v at rennlist.org>; <quattro at audifans.com>
Sent: Saturday, June 23, 2001 8:44 AM
Subject: differential plug removal


> 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
>