Another Diff Plug /cover Question

[MikeInCtown]

So I too have a problem getting the diff plug out of a bravada with the limited slip rear end. Everything is rusted under there and the diff cover is starting to leak pretty bad. I have no impact gun in my garage or air for that matter.

 

I'm wondering if this would work: Buy a trans pan drain plug kit and put it onto the new diff cover I have. I would drill slightly off center of course to avoid the ring gear, but I'm thinking there should be enough room. Then i never have to worry about the fill plug.

 

-OR-

 

have a welder weld a nut on the outside of the cover and use a regular plug with teflon tape on it. Then nothing sticks into the diff.

 

I need to do this soon though. Any opinions welcome.

[alwcurlz]

So I too have a problem getting the diff plug out of a bravada with the limited slip rear end. Everything is rusted under there and the diff cover is starting to leak pretty bad. I have no impact gun in my garage or air for that matter.

 

I'm wondering if this would work: Buy a trans pan drain plug kit and put it onto the new diff cover I have. I would drill slightly off center of course to avoid the ring gear, but I'm thinking there should be enough room. Then i never have to worry about the fill plug.

 

-OR-

 

have a welder weld a nut on the outside of the cover and use a regular plug with teflon tape on it. Then nothing sticks into the diff.

 

I need to do this soon though. Any opinions welcome.

 

That plug should have a square hole, 3/8". A 3/8" ratchet will take these out. I would put a ratchet in there, and start with the top filler plug first. You may need an extension. I would then take a hammer and with pressure on the ratchet tap/strike the ratchet handle which should pop the plug loose. That's how it worked for me!

Good luck!

[2COR517]

Did you read this thread?

 

http://www.gm-trucks.com/forums/index.php?...c=99967&hl=

 

I know it doesn't answer your question about adding a fill plug to the cover, but there's some good advice on getting the original plug out. If you decide to add a plug to the cover, I would suggest starting with a new cover, so you get a good gasket seal. Plus it will be nice and clean for a solid weld.

[MikeInCtown]

Yes, I did read that thread, whih is why I said I also have a problem. I've tried hitting a socket extension in there to no avail. I've even taken a screwdriver/chisel and tried to clean out and square up the hole to no avail.

 

I do have a newer cover that has no rust on it and it seems fairly thick. The last thing I want to do is screw up the original plug/housing when I might be able to do it easier and as a long term solution. I mean the old covers used to have plugs in them, no? Plus there is more room behind the diff so filling may be easier lol.

[WilliamBos]

How are your welding skills?? That happened to me on an 83 K2500. My Dad had to weld a nut on it to get it out. As soon as we got it out, we put a male plug in. Never a problem again!!

 

Some aftermarket covers have plugs in them. I hope others chime in here, because that sounds like a good low cost solution too.

 

Yes, I did read that thread, whih is why I said I also have a problem. I've tried hitting a socket extension in there to no avail. I've even taken a screwdriver/chisel and tried to clean out and square up the hole to no avail.

 

I do have a newer cover that has no rust on it and it seems fairly thick. The last thing I want to do is screw up the original plug/housing when I might be able to do it easier and as a long term solution. I mean the old covers used to have plugs in them, no? Plus there is more room behind the diff so filling may be easier lol.