Differential Fill Plug

Bolt snapper · Oct 28, 2018

Trying to get caught up on maintenance on my '04 Eddie Bauer, since I don't know the history. I think I've read that the differentials are supposed to be "lifetime" and not serviceable, but I thought I'd try to open the fill plugs on both front and rear just to make sure fluid levels were full. Maybe pull a sample and see how dirty the fluid is. But after four straight days of PB Blasting the fill plugs, I can't budge them.

Is this normal? Any tricks to breaking them loose?

Habbibie · Oct 29, 2018

I used a battery Milwaukee impact gun set at the highest setting, unscrewed it on the first try

The impact motion breaks the rust bond immediately, I dont think an impact "driver" has the power, you'd need one of these bad boys. Maybe you, a friend or a coworker has one you can borrow.

Black · Oct 29, 2018

Heat!!
Don’t feel bad I am still trying to crack the fill plug on my 2016.
Bought a new MAP tank today hoping to pop it tomorrow.

1997SCEBFEX · Oct 29, 2018

different model year, but passing on my experience:
used a 1/2 in ratchet and tapped with a rubber mallet to loosen on my '97 differential when I changed it back in '12.
also suctioned it out vice removing the diff pan bolts.

don't forget friction modifier if you have the LS rear, and I used synthetic.

1955moose · Oct 29, 2018

Heat the plug with a torch. They use red Lok tite on the threads, why is beyond me. Then get a long 1/2 in drive breaker bar, 18 to 24 inch, and have at it. Should bust loose , remember lefty or counter clockwise for loosey.

Sent from my N9131 using Tapatalk

Hamfisted · Oct 29, 2018

It takes a 3/8" breaker bar. May need to add a length of pipe to the breaker bar for added leverage. I wouldn't call any of the fluids in a Ford "Lifetime" fluids. A bad seal will trash an axle if you let the "Lifetime" fluid get too low. Make checking axle and tranny fluids part of your normal preventive maintenance schedule.

Habbibie · Oct 29, 2018

A half inch breaker bar with a reduction adapter 1/2" to 3/8" would work too, that's what I used on my 1/2" impact gun

Black · Oct 29, 2018

Heat!!!! Will pop it right off they are locktited.
Did mine today

Habbibie · Oct 29, 2018

I'm assuming the OP doesnt have either a torch nor an impact gun.... point of the story is get one or the other and your solution is within grasp!

Bolt snapper · Oct 29, 2018

I don't have a torch (but if you're saying a MAPP torch will get it hot enough, I may pick one up). I don't have a battery-operated impact, but I do have a pneumatic. I'll have to look to see if I have enough clearance to get at it.

Thanks!

Differential Fill Plug

Bolt snapper

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