How to get off a stuck diff fill bolt?
 

I changed my tranny fluid this weekend and it was horrible smelling/looking and the drain bolt had metal shavings on it.....not good. It didn't look like it had been changed for a long time, so the diff fluid probably hasn't been changed forever either. How would you guys get off a frozen diff fill bolt? I've tried using a long pipe as a breaker bar, but even with all my weight hanging on it, it wouldn't budge. I soaked it in WD-40 for a good 20 minutes and tried again, but nothing. The bolt is starting to strip, but I can still get a good grip on it. What do you guys suggest? Good thing I didn't drain it.

blue flame wrench maybe? or get a longer breaker bar.

What's a blue flame wrench? A longer breaker bar is kind of hard since I'm doing it on jackstands, and it's in a compact place, but I will see what I can do.

You can try heating the bolt (just be VERY careful with flame in that area). Mine was stuck on there two but I was able to get it off with a little umph. Have you tried PB Blaster? I've found it works MUCH better than WD-40.

Tranny/diff fluid smells awful no matter how old it is.

Some shavings on the drain plug are perfectly normal.

As for your stuck plug problem I'd try heating it with a torch a few times before breaking it loose.

Good deal. Tip everyone should always follow: Never drain anything without first verifying you can remove the fill plug/cap etc to refill it afterwards!

i bet an impact gun, and some GOOD penetrating lube (not wd40) will get it off. spray some on there, hit it with impact, spray more, hit it. after 2 or 3 cycles i bet it comes right off.

A friend also suggested heating it with a torch. I didn't think it was such a good idea, since it's right next to the gas tank, but I will give it a try with a careful hand. I'll also try some of that PB Blaster. Can I pick it up at AutoZone or Kragen?

I would use an impact, but I honestly don't see how you could fit an impact wrench in the small space there is.

Thanks for the input guys.

AutoZone should have it.

I was unable to get my impact gun back there, no even close.

I let mine sit for awhile with pb blaster....then I placed the wrench on there and then stuck my foot on the end of the handle and I was able to use my legs to knock it lose ... Mine as well was on jack stands...while it is already on jack stands, trany fluid change and if you haven't already replace or relocated the fuel filter... good luck

I second that.

Along with this, try alternating between 'tighten' and 'loosen,' this can help to shock the bolt. If you use an impact u-joint along with an extension you may be able to get in there at an angle with the impact gun.

pb blaster...i luv that stuff......
heat...little propane tank...
and like said already...try tighting it first, usually breaks it loose...
you can also tap on it with a hammer ...
good luck

brad

a good box wrench with a few blows on the other end from a small sledge to lossen, aka ghetto impact

Why can't you simply remove the whole rear cover? You'll have a little oil mess, but almost all of it is already drained. Plus you can check the gears for wear.

It could be a lot easier to 'coax' off the fill plug when it's off the car.

Dave