diff / gearbox refill plugs

[Christophski]

If you have to use Allen keys to undo or tighten them and they are rounded, get a spline/star one that is slightly larger and hammer it in. This will then allow you to undo the stuck, rounded item.

[4WheelDrifter]

If you have to use Allen keys to undo or tighten them and they are rounded, get a spline/star one that is slightly larger and hammer it in. This will then allow you to undo the stuck, rounded item.

Never use Allen keys on drain plugs. Always use a hex bit socket and a nice long breaker bar to minimise the chance of rounding the plug.

[Gazmitchell]

well ive tried welding a nut and a bolt to plug but no go .,so corroded cant get enough clean metal and just snaps off... how easy is it to remove cover and can it be done in situ ? typical small job turning to a major one !!!

[Christophski]

Tried hammering in the torx drive (star shaped) or a spline tool into the rounded hole? This has not failed me yet with rounded allen key bolts....

[Gazmitchell]

done it at last.. cover off and did on the bench... now for the gearbox !

[jeffstoo]

Just had the same problem with drain plug on diff. Tried brute force,hammer,heat,freeze spray all no joy. In the end i cut an M10 bolt to about 30mm, cleaned it and plug as best i could, welded bolt into hex and BINGO. I am now using the newer spline type plugs which seem to provide more grip.