7.5 differential fill plug

[Bird76Mojo]

If you're going to try the wax route to loosen it up, only use pure paraffin wax. Most other wax blends don't melt down to be nearly as thin as pure paraffin.

 

[Elijah1989]

Thank y’all for the ideas! I plan on getting back to try it on Thursday. I’ll keep y’all posted. My fingers are crossed the heat works

 

[Elijah1989]

Update here. Heating did not work. I heated again and put ice on the plug itself and that didn’t work. I’ll be going to pick up some wax here soon to see if that will help loosen it.

If not I guess I’ll measure how high up the fill plug is and drill a hole in my cover and put a plug in.

 

[Elijah1989]

None of it worked and the impact drill stripped out the bolt once I heated it up for the wax.....

I guess I’ll fabricate a cover with a fill hole.

Thank y’all for the help. It was much appreciated.

 

[Elijah1989]

The old dodge 9.25" rears had a simple 3/4" hole in the cover with a rubber plug. Simple and effectve to add on if it's driled at the proper level.

Do I just drill out a 3/4 hole in cover and use that plug? No leakage or anything?

 

[Dirtman]

Well i would find a plug first then drill to that size. I dont know if you'd be able to still find those old chrysler plugs exceptnat a junkyard but you could easily find any size rubber sheet metal plug you want online. And the one in my ramcharger never leaked in 30 years....

 

[Elijah1989]

Well i would find a plug first then drill to that size. I dont know if you'd be able to still find those old chrysler plugs exceptnat a junkyard but you could easily find any size rubber sheet metal plug you want online. And the one in my ramcharger never leaked in 30 years....

I searched for dodge 9.25 differential plug and found an abundance of them. I think that will be my out for this

 

[Curious Hound]

skip forward to about the 2 minute mark and try this.

broken screw, etc. removal.

 

[Dirtman]

I searched for dodge 9.25 differential plug and found an abundance of them. I think that will be my out for this

Just remeber you'll never get that plug in the perfect spot so you will need to fill to the exact amount needed in the owners manual and not just fill till it comes out of the plug.

 

[Elijah1989]

skip forward to about the 2 minute mark and try this.

broken screw, etc. removal.

Link wouldn’t open.

 

[Elijah1989]

Just remeber you'll never get that plug in the perfect spot so you will need to fill to the exact amount needed in the owners manual and not just fill till it comes out of the plug.

Gotcha. Thank you for the info.

 

[Curious Hound]

so

Link wouldn’t open.

sorry. I fixed it now.

 

[Elijah1989]

so


sorry. I fixed it now.

If it wasn’t stuck in there I would try this. Thank you sir.

 

[Bird76Mojo]

What are you using for your source of heat? I'd guess you need it much hotter.. Not the plug itself but the diff case around it. One of the best sources to get things super cold is the cans of Keyboard Duster that Walmart sells. Turn the can upsidedown and it will freeze anything known to man. Heat the case around the plug with a cutting torch (be careful to not hit the high pressure oxygen lever) and then use the can of Duster turned upsidedown to freeze the plug by squirting directly in to the middle of it.

If nothing else, I'd get an old steel nut that the zinc coating has rusted away on, and lay it flat on the diff plug and either stick weld it to the plug or mig weld it on high heat.. Until the inside of the nut is filled with weld. Let it cool for about 2 minutes or so, then try removing it..

Either that or cut a piece from an allen wrench, insert it in to the fill plug and weld around it as solidly as possible to the plug. Same process for removal... The weld won't really stick to the cast iron differential case just in case you accidentally overlap the plug..

It could also be drilled out fairly easily. Then knock the remaining part of the plug out with some small punches/chisels and a hammer.. If you do drill it and decide to try an "easy out" then be SUPER careful to NOT break the "easy out" or you'll have a much larger problem from there on out.

 

[Curious Hound]

If it wasn’t stuck in there I would try this. Thank you sir.

I've used that method on some very, very stuck threaded things over the years.