stripped rear differential fill allen bolt
#16
Like Salim said before, That idea with the chisel works great. IF you can see the plug from the side view. I have had very good luck doing rusted fasteners this way. Another way is to ***** punch the surface on the outer edge, and "drive the screw out" Same idea as that panel cutter, just slower.
-Quick heat can sometimes work wonders...
barryst
-Quick heat can sometimes work wonders...
barryst
#17
Lexus Champion
Removing fill plug
One thing I didn't think about (unfortunately also requires tools you may not have) is to use an air operated file, air saw, die grinder with cut-off blade, a hand hack saw and may be other things in addition, and cut a square edged slot. Then if you had a piece of cold rolled strap that fit in the slot that you made and use a large cresent wrench to back it out (just like a LARGE screw driver in a nice square edged slot about 3/16 wide. If it's that tight regular soft steel might work but cold rolled would do the trick. I have a special type of easy out that I think would do the trick, but it's not worth it to buy them because you have to buy the set and pretty expensive. Have a ton of special tools and would be glad to help if you were local but the most practical would be to let a professional do the job. (and that doesn't mean AAMCO or Pep Boys!!!)
#18
Driver
Thread Starter
I soaked the bolt in liquid qrench over night and tried to open it with the chisel and hammer but the chisel keeps on eating the metal instead of losening it. Every time I hit it, it cuts piece of the bolt off. I think I am gonna take it to the local shop and have them take care of it.
#19
Lexus Champion
I soaked the bolt in liquid qrench over night and tried to open it with the chisel and hammer but the chisel keeps on eating the metal instead of losening it. Every time I hit it, it cuts piece of the bolt off. I think I am gonna take it to the local shop and have them take care of it.
#20
Moderator
You give it a good shot. Let some one do it for charge.
The reason it is slicing is that the threads are bonded too strong and that would require a deeper notch, before giving it a twisting blow.
My gut feel is that the mechanic is going to apply heat. Do take the new plug and don't forget the anti-seize.
I am willing to bet it is different composition on the plug and diff, and with time they have electrically bonded.
Keep looking at the bright side, that you did not drain the diff.
Salim
The reason it is slicing is that the threads are bonded too strong and that would require a deeper notch, before giving it a twisting blow.
My gut feel is that the mechanic is going to apply heat. Do take the new plug and don't forget the anti-seize.
I am willing to bet it is different composition on the plug and diff, and with time they have electrically bonded.
Keep looking at the bright side, that you did not drain the diff.
Salim
#21
Driver
Thread Starter
code58,
You are right. I have should have been more careful when attempting to losen the bolt. I have not really delt with a stuck bolt like this before but this is definately a lesson learnt the hard way. If I ever come across a frozen bolt now, I would definately take a more careful approach and keep it from stripping.
salimshah and others, thanks a lot for your help.
You are right. I have should have been more careful when attempting to losen the bolt. I have not really delt with a stuck bolt like this before but this is definately a lesson learnt the hard way. If I ever come across a frozen bolt now, I would definately take a more careful approach and keep it from stripping.
salimshah and others, thanks a lot for your help.
#22
You give it a good shot. Let some one do it for charge.
The reason it is slicing is that the threads are bonded too strong and that would require a deeper notch, before giving it a twisting blow.
My gut feel is that the mechanic is going to apply heat. Do take the new plug and don't forget the anti-seize.
I am willing to bet it is different composition on the plug and diff, and with time they have electrically bonded.
Keep looking at the bright side, that you did not drain the diff.
Salim
The reason it is slicing is that the threads are bonded too strong and that would require a deeper notch, before giving it a twisting blow.
My gut feel is that the mechanic is going to apply heat. Do take the new plug and don't forget the anti-seize.
I am willing to bet it is different composition on the plug and diff, and with time they have electrically bonded.
Keep looking at the bright side, that you did not drain the diff.
Salim
#24
Lexus Test Driver
I never thought of welding something to the old plug. That's something I couldn't do myself, but I caould have someone do it for me the next time I'm in a similar pickle! Great idea!!
#25
Lexus Champion
code58,
You are right. I have should have been more careful when attempting to losen the bolt. I have not really delt with a stuck bolt like this before but this is definately a lesson learnt the hard way. If I ever come across a frozen bolt now, I would definately take a more careful approach and keep it from stripping.
salimshah and others, thanks a lot for your help.
You are right. I have should have been more careful when attempting to losen the bolt. I have not really delt with a stuck bolt like this before but this is definately a lesson learnt the hard way. If I ever come across a frozen bolt now, I would definately take a more careful approach and keep it from stripping.
salimshah and others, thanks a lot for your help.
#27
Lexus Champion
#28
Moderator
The drain plug due to vehicle clearance issues needs to be an "innie" [like the navel]. Else when bottoming out, the drain plug can get sheared. Although the filler can be a regular bolt with head, but since the differential is spherical in shape, the easiest seal is accomplished by yet another innie.
Moral: There is always a reason why the things are built the way they are. It can even be cost reducation due to sharing of components etc.
Salim
Moral: There is always a reason why the things are built the way they are. It can even be cost reducation due to sharing of components etc.
Salim
Last edited by salimshah; 09-17-09 at 06:50 AM.
#29
Lexus Champion
#30
Looks like there is still a little but of corners there for a 10mm driver 3/8 socket to fit in. Insert the 10mm allen, tap it with a hammer a bit, then use a 3/8 ratchet to loosen it.
Like this
http://buy1.snapon.com/catalog/OBJECTS/43300/43244.JPG
Like this
http://buy1.snapon.com/catalog/OBJECTS/43300/43244.JPG