Well, I have been doing some routine maintenance on the wagon. Today I was going to drain and fill the diff. Of course, prior to draining the diff I was going to make sure the fill plug came out. The PO rounded it out. I have the proper 14mm hex wrench, but it just slips when any pressure is applied. Is there anything that can be used to remove the plug? I do NOT want to drill it out. Thanx in advance for all of your help again.....

__________________
1984 300D Turbo Sedan (Hilda) 272,115 miles.....
Anthracite Gray/Palamino Leather, I am 3rd owner

2001 Dodge Stratus (Silver) (wifes) 55814 miles...

1982 280TE Wagon Astral Silver Metallic/
Anthracite Velour
260,512 miles (Eva)

1969 230 Sedan Olive Green/Black MBTex
4 Speed Manual
84,213 miles ????
Haus Frau


2004 Boreem Ninja Pocket Bike
Highly Modified 49cc (Ling Ling)

Einigkeit und Recht und Freiheit

Clean the hole really well... like with Brillo pad and then alcohol ... also do that to the shortest bolt you can find which has the largest head which will fit into that hole.
Then mix up a small amount of the strongest epoxy you can find... JBWeld, etc... and place the bolt head in there and leave at least 24 hours without allowing it to move...... . depending on temperature...
Then take a couple of nuts which fit on that bolt and screw them onto it...and use them with a breaker bar to loosen it.
If you need to put your car jack into the hole on the right rear of the car...and attach a comealong to the breaker bar... this gives you a lot of force but in a controlled way.... not like an air wrench... I have posted pictures of that arrangement in the archives..

Leather's directions will work very well. If the plug is available as an orderable item, try taking the whole pumpkin cover off, do leather's thing or try to wedge some pieces of metal in place to hold the hex thing tight. Then use an ELECTRIC impact wrench on it, not a monster air wrench. Now, I did the electric part on mine that was virtually impossible to remove. I didn't have the rounded out problem. It took about 30~45 seconds of impact wrench hammering to break it loose but all was well after it came out. I found being able to rest the pumpkin cover on a pice of cardboard on the ground gave me much better control to avoid any damage. Good Luck.

Heck , I was hoping no one else had posted... because my instructions will only work if that bolt is a left hand thread... not worth trying to find that....
I would just weld the nut onto the bolt.. but I try not to assume the availability of welding equipment in my answers...
If you use two nuts on the bolt and put JBWeld on those threads... and tighten the nuts AGAINST each other before they start to set up that might work...

With enough JB weld, anything is possible.

An air impact wrench usually has torque settings so you can 'tone it down' for more gentle jobs. You can also run them at a little lower than normal pressure, like 80 or 70psi to soften them up even further. Just as a hint.

leathermang's method should work fine, but if you are disassembling things anyway, taking the cover off and putting it on the ground would probably make the job easier, just because you've got more room to get a good angle on it.

peace,
sam

__________________
"That f***in' biodiesel is makin' me hungry."

1982 300TD Astral Silver w/ 250k (BIO BNZ)
2001 Aprilia SR50 Corsa Red w/ 5.5k (>100 MPG)

I don't know.. if you take it off how are you going to hold it ? This is not a really thick piece of metal... not much way to Evenly hold it without warping it.. I think doing it on the 3rd member if possible is the way to go...