Sheared the diff plug....

[kingfishers2]

I attempted to remove the drain plug from the rear diff yesterday and after about 2 turns it rounded of! im sure this is pretty common as most probably never get removed.
Has anyone experienced this and found a decent solution? ive contemplated drilling it out with a holesaw and relacing it with a slightly bigger bung, how close are the internals to the rear of the plug?

[lind4hl]

they are pretty close if i remember correct, or is that the fill plug

did you hammer in the socket far enough?, i made that mistake one time ( lucky it was on the V8 differential..)

[kingfishers2]

I hammered the socket in then had to apply an insane amount of pressure with a large breaker bar it finally cracked, then let go after a couple of turns.
The main worry is while all this was going on oil was seeping out of the rubber valve on top so im going to have to remove it what ever happens.

[lind4hl]

is the diff out of the car? since it is leaking oil from the top, that is just an ventilation..

what about an tool like this?
(english word?)

[kingfishers2]

Thats a set of Stillsons, some people may call them other things! The diff is out of the car but the plug is inverted i used a large hex socket can,t remmember the exact size 22mm?

[lind4hl]

yes, but the plug sticks out a bit from the housing right? you may get it loose,

did the plug loosen a bit or is it rock hard thight?

[kingfishers2]

Its bloody tight

[lind4hl]

then you probably can forget the stillsons.. a freaking amount of 5-56 or something similar and a sharp iron to hammer it loose, understand?

[kingfishers2]

Sounds like a plan i wonder if the plugs are still availiable from audi?

[lind4hl]

maybe

part number 111 301 127E M24x1,5

[kingfishers2]

Nice one cheers!

[fish]

Try the Omega 636 creep-oil, thats a proper miracle fluid! Expensive, but well worth it!

[s2driveruk]

heat or freeze should help crack it off....failing that mine had to have a 17mm nut welded to it before it would let go.

[Error404]

I have had this issue with Davids /\ old diff

I eventually took the diff out of the casing and took to to a machine shop and had them drill it out and retap it and then make me a nice big stainless steel plug for it