Diff fill plug pt XXV

[Shern]

This has been beaten to death but bear with me.

I’ve had the diff open to change torn axles twice in the last 6 years.
The last time however, I had to farm the work out. I was away from my jack and stands and needed the new axle on asap.

I’m out here doing routine fluid changes and I cannot crack the damb thing loose.
Full picture: I’m on my back using a quality allen socket (properly seated, before the brigade comes in) on a 1/2” breaker bar. I suspect the mechanic who installed the axle reinstalled the plug with an impact gun.

Things I’ve not done: penetrating oil, even longer cheater bar.

Is there any danger to the diff housing cranking on this thing with an even longer breaker bar?

[Sugar Bear]

Shern,

Is there any danger? I'll never say never and the question is a fair one. IMO the risk is very, very low re: cracking the housing. I've never seen it in fifty years. If it's just a fluid change let it go if someone in the area would break it loose on a lift.

Good luck!!!

[Diesel911]

As was said in post #2. I have not read of anyone cracking anything removing the plug. I have not read of anyone stripping out the inside of the hex either.

[barry12345]

I have had to use a four foot extension pipe on a breaker bar to get the rear end bungs removed on these cars.

On occassion. They let go with a ferocious bang. Yes one would think a chunk of the housing was going to break out first .

Not on a lift you would have to get the angles right and probably use a floor jack under the bar to generate enough force.

The reason they may be so tight is the design of the threads has to prevent metal to metal seepage. You would be better and safer with the car on a hoist. Remember top one first then the lower one. Maybe consider using teflon plumbing tape when you put them back in.

I might use a floor jack so I would not be under the car if not on a solid lift. I cannot remember now but think they are a 14 mm allen key.

So large enough to take quite a force. Never have seen a member mention the housing broke. A good impact gun might move them. Never tried that myself.

[JHZR2]

They always get super stuck. Long breaker bar, maybe a cheater, press with legs. Yes, have had to do it on many cars.

If you have an impact gun, I’ve used that once and it works good.

[tangofox007]

Originally Posted by Shern

Full picture: I’m on my back using a quality allen socket (properly seated, before the brigade comes in) on a 1/2” breaker bar.

Not all breaker bars are created equal. The difference between 18" and 25" can be pretty amazing. I frequently use a 25" S-K that has yet to be defeated by a stuck fastener or drain plug.

[JHZR2]

Originally Posted by tangofox007

Not all breaker bars are created equal. The difference between 18" and 25" can be pretty amazing. I frequently use a 25" S-K that has yet to be defeated by a stuck fastener or drain plug.

Agree that the 24” length is good to use. I’ve had some that needed a cheater on the end. Maybe it’s less of an issue if up on a lift. But if doing it with the car on the ground, or maybe up in a bit of lumber (don’t need to raise the cars up much if at all to access the diff fill/drain), there’s not much swing and it’s hard to get the torque.

But I’ve definitely had to use leg strength on a breaker bar before. The w123 cars seem worse with this than others. The plugs on my w140 are super easy.

[psaboic]

I had a super stuck plug once. I took it to the local shop and had them break it loose for me. Cost me $20 but the onus was on them if they broke something, and it saved me from hurting myself if something slipped when I was applying force. Its a matter of opinion, but it was worth the $20 to me.

[Zulfiqar]

you may need to use a torch to warm up the housing around the plug, let it drink some PB blaster while at it too, then use your tool and crack it loose.

[imgolden]

If it makes you feel better, there are 3 W123s in various yards down here in San Diego. Worse case scenario, I snag you a diff cover at the yard if yours breaks.

[Shern]

Originally Posted by imgolden

If it makes you feel better, there are 3 W123s in various yards down here in San Diego. Worse case scenario, I snag you a diff cover at the yard if yours breaks.

Dude that’s a real solid, thank you.

Thank you to everyone else as well. My breaker bar is only 18”. Kind of a junior breaker… will cautiously proceed with force multiplier.

[Shern]

Success.

A tire iron with me leaning on a 5' 2x4.
Meanwhile, all the drain plug took was "please."

I forgot how diabolical that gear oil smells...


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[Sugar Bear]

! GOAL !

[Sugar Bear]

I hated getting that gear oil drip in my hair... don't have hair anymore...

[123boy]

I LOVE the smell of gear lube! (a.k.a. hypoid oil) Reminds me of my youth and wrenchin with my dad...
Glad to learn the drain plug came out!