Rear diff fill plug STRIPPED. Pinion seal leaking. Totally F'd

[CanukGMC]

So do I drive until the diff blows? Thos RETARDED square drain plug bolts are the bane of my very existence on this planet. Why use a bolt when you can use a square!

Tried welding a bolt into the rounded hole to extract it, got burning embers in my EAR and have no room to see what im doing under there with a welding lid on.

Wtf do I do? My brother needs to be able to drive

[MT-2500]

I the pinion seal is leaking you need to replace it before you burn up rear end.
at least get greese in it before driving any.
Also check pinion bearing.
Is the bearings lose or rough?
Did grass or weeds get in pinion seal.
Is the rear end vent stopped up?
Is rear end making any noise?
http://www.differentials.com/install.html

On the filler plug if you can not get it out by welding a bolt in it.
You will need to drill out and use a easy out to remove it.
After drilling out remove the inspection plate and clean out shavings and metal chips.
MT

[CanukGMC]

Originally Posted by MT-2500

I the pinion seal is leaking you need to replace it before you burn up rear end.
at least get greese in it before driving any.
Also check pinion bearing.
Is the bearings lose or rough?
Did grass or weeds get in pinion seal.
Is the rear end vent stopped up?
Is rear end making any noise?
http://www.differentials.com/install.html

On the filler plug if you can not get it out by welding a bolt in it.
You will need to drill out and use a easy out to remove it.
After drilling out remove the inspection plate and clean out shavings and metal chips.
MT

Pinion seal leak is a very slow one. I have zero money and no patience left for auto repair (every vehicle I've come accross has died this week and I'm up to my face in busted knuckles and burns). So what you are saying is there is no other way to remove the fill plug other than drilling it. These fill plugs were the worst idea I've ever seen, I don't know who is chuckling over this design from their graves but I'd like to punch him in the neck. I'll bring it to the shop with the other trucks, I own 3 sets of ez-outs and NEVER have I ever had one even bite into anything I've drilled out (yes using the right size drill) the ez out just spins or strips the hole out but never ever turns the bolts. Rust=the strongest glue known to man.

[blazes9395]

While its always best to try to get that plug out, its not necessary. An easy way to get around this(I have does this several times, on many diffs, all successfully), is to install a drain plug on the rear cover. You roughly put it at the same level as the stripped plug and you are good to go. I use those plugs within a bolt kits, which are sold at Canadian Tire. Works like a charm and you avoid pulling all your hair out.

[CanukGMC]

Originally Posted by blazes9395

While its always best to try to get that plug out, its not necessary. An easy way to get around this(I have does this several times, on many diffs, all successfully), is to install a drain plug on the rear cover. You roughly put it at the same level as the stripped plug and you are good to go. I use those plugs within a bolt kits, which are sold at Canadian Tire. Works like a charm and you avoid pulling all your hair out.

Good info, I've calmed down a bit (surrounded by mechanical failures this week) and was thinking about it. I'm going to bring it to the shop when I get a chance and see if they can yank the seal (don't feel like fighting the rust). If they can't fit me in for a week I think I'll pull the rear cover, throw it on the drill press and then maybe weld a nut onto the outside of the cover to screw a stubby bolt into. Personally I think installing ANY threaded fitting into the diff case itself is just stupidity, my YJ had a fill plug built into the cover on both its diffs and even if there was a problem then worst case scenerio you buy a new cover. It's only logical.