Differential Filling Cap

[hawksa]

Any tips on getting the filling cap out of the differential? I have tried a t-bar 10mm Allen key but I can't shift it!

 

Thanks,

Simon.

[mikef]

I had exactly the same problem recently.  Even with a breaker bar and a friend's muscle it would not budge even after soaking with Plus Gas.  I wasn't too keen on applying heat since it a bit close to the fuel tank.  In desperation, we dremmelled a slot in the plug and tried a cold chisel but to no avail.

 

Eventually, I took off the complete back plate and took it to a local welder who welded a bolt onto the plug and used an air gun which finally got it out.

 

Needed a new plug but at least it is now filled with fresh oil.

 

Hopefully, you won't have to go down the same path.  Others might have some better ideas.

[Ian Kinder (Bagpuss) - Joint Peak District AO]

Impact driver(if you can get it in). Or jack it up and arrange ratchet so that when you lower the car the weight helps undo.( not done this on a Westie though).

[TableLeg]

They can be a real pain in A.

 

If you do manage to get it out maybe consider replacing the Steel plug with one of these Alloy ones

http://www.ebay.co.uk/itm/Mishimoto-Magnetic-Oil-Drain-Sump-Plug-M20-x-1-5-Black-/331361841086?pt=LH_DefaultDomain_3&hash=item4d26b46fbe

 

http://www.ebay.co.uk/itm/Magnetic-Oil-Sump-Drain-Plug-Nut-Subaru-Impreza-WRX-STi-Turbo-2000-GC8-GDB-GDA-/131168335063

 

 

 

Alloy to Alloy is better than Steel into Alloy in terms of thread corrosion reduction.

 

Good luck.

[Lyonspride]

I would suggest a breaker bar with a jack under it, just apply a little pressure (enough to move the end of the bar by an inch) and leave it over night (or a couple of days), far better than it suddenly letting go and taking out something valuable.