diff / gearbox refill plugs

[Gazmitchell]

Hi all, can someone tell me where exactly the refill plug is on the gearbox cant see it for toffee !, wanna try these first before the drain plugs, and any idea what size hex it and the diff plugs are please, cheers

[Error404]

drain is on the bottom!

the filler is on the front diff cover, about half way up

[UrS4boy]

Rear Differential Fill Plug location

Hi all, can someone tell me where exactly the refill plug is on the gearbox cant see it for toffee !, wanna try these first before the drain plugs, and any idea what size hex it and the diff plugs are please, cheers

Good plan. *ALWAYS* make sure you can get the fill plug out *BEFORE* you try removing the drain plugs.

Here is a photo of a rear diff showing the fill plug on the right side flange. (Photo is from someone here - Thanks). Front will be similar.

[Gazmitchell]

Lol did find the drain plugs ...

Was the gearbox one I couldn't see, but found em all now... diff drain, no prob there moves easily , but filler plug a no no, plug is corroded and loose over the 17 mm Allen key so gonna be fun and games with it...

[John B]

Yes, been there a few times. the plugs are tapered and quite often are over-tightened. They should only be nipped. Some heat and penetrating spray with a long bar usually sorts 'em out. Good luck

[Morris400]

Any one have the part number for the rear diff fill and drain plugs on a 94 urs4?

[UrS4boy]

Rear Differential Fill Plug location

Any one have the part number for the rear diff fill and drain plugs on a 94 urs4?

111301127E Items 4 (3 of them, 2 drain on the bottom, 1 fill on the right side)

[Morris400]

Thanks a million.

[mcandmar]

If you should drain the box before getting the filler bung off you can remove the speed sensor and fill through there, likewise on the rear diff you can remove one of the bolts around the diff lock. It will be tedious so treat it as a get out of jail card.

[Gazmitchell]

good call, thanks for that, ive got new plugs on way from TPS, so its gonna come out one way or tother !, may end up drilling it out if I can get on it - do have one of them right angle drill ends so possibly be ok that way.

thing was it did actually turn , but tightwise, but the inverted hex was rounded loosewise, guess as its been overtightened in the past, so if the kin hex was tight it prob would have undone! but you cant get on anything to drive a larger size into it cuase the subframe and shaft are so close..

just wondering whether to drain then drill , or drill then drain and flush........

[mcandmar]

I would not entertain the idea of drilling it out, you wont be able to get all the bits of swarf out. Instead i would remove that entire diff cover from the gearbox and do it off the car.

Your best bet is to get a nut welded into the bung.

[Error404]

Try tapping it round with a cold chisel, since it is not seized in there it should be pretty easy

[Gazmitchell]

I did try with a tap n chisel but didn't seem to wanna move anticlockwise... it is a normal thread isn't it ? will persevere with the cold chisel route for now ..

[s2driveruk]

i always coat the thread on mine in some moly to help avoid having that fun...seems to have worked well so far topped up the rear diff last weekend and it opened up no worries. Could always try some freeze spay on it, usually works a treat.

Good luck

[Gazmitchell]

Yep... what I will do with new the plugs....

Gearbox filler plug same, rounded and sloppy on the allen key bolt will be welding a nut on that also I guess....