quote:

Originally posted by Oldrider:
It isn't just your Ford that has that problem, tried removing the plug in my Colorado's rear axle last week. No joy. Those plugs are so tight I don't think you could chisel, beat or any other applied force would break it loose. I think it's a real possibility you could crack a housing trying to get it out.
Greymann's second idea actually sounds like a winner. Your differential cover is probably sheet eteel so drilling it out for a bung you could tig-weld on would be very doable.
Thanks for the idea!

quote:

Originally posted by egregore:
Ford? This is on your new Expedition?? Makes you wonder what else is rusted.

I don't see filling the hole with glue working. I think it would just shatter and fall out. If the drive hole is completely rounded out, and you have air and an air hammer, about the only thing you can do is try to catch an edge (if any sticks out) of the plug or the inside of the hole and try to "walk" it out with the chisel bit. Sharpen the chisel so it bites in and is less likely to slip out. I'm sure you've been soaking it in penetrant. Do you have an oxy-fuel torch? If the differential case is iron, heat it up until it just starts to glow red. Be very careful if it is aluminum. These plugs are typically a 3/8" pipe thread male plug.

quote:

Originally posted by BigSwede:
Pretty sure it's synthetic, I would leave it alone

quote:

Originally posted by egregore:
You were smart to try and get the fill plug out first. Had you pulled the drain plug first you'd have had no way to refill the diff. Removing the fill plug first also lets it vent and drain more thoroughly.

quote:

Originally posted by BigSwede:
Pretty sure it's synthetic, I would leave it alone

You must not know the OP very well.

quote:

Originally posted by signewt:
Not the plug but I can vouch for unexpected success slathering ample sheet onto the front corner of an oil pan that had nicked a rock and leaked most of the contents out.

Afternoon pan removal, sort of a thick icing on both sides in & out & thru the remaining crack ub the metal, overnight dry, & that sucker held up for the next 100,000 miles.

quote:

RED THREAD LOCKER!!!!!!!
That is why the bugger would not come off. Grabbed a new factory plugs today and sure enough RED thread locker. So once I get the fill plug out I will certainly be heating up the drain plug before trying to remove it.

quote:

Originally posted by benny6:
I'd hit it with a heat gun or a portable torch. If you still have enough for the breaker bar to grab, try that with the heat. If not, use the chisel.

Tony.

quote:

Originally posted by 4MUL8R:
The lubricant in the Ford axles is high quality. It is tested for far more abuse than you can ever imagine. I have personally tested the axle lubricant in NW Arizona in a Ford pickup employing their test method and we wore out three transmissions and about seven sets of tires before the full test duration was complete. Although changing the lubricant is going to give your vehicle extended life, it is quite well designed and validated for the expected vehicle life.