stripped rear differential fill plug - Ranger-Forums - The Ultimate Ford Ranger Resource


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Old 06-08-2011
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stripped rear differential fill plug

Hey guys, I was wondering if it matters if I fill my rear differential gear oil through the axle breather hole?? My fill plug is stripped and I already drained the fluid out of the case (I know stupid I didn't check the fill plug first.) So would it be a problem unscrew the breather valve on the axle and put it through that hole? If so should I jack up the truck so it would flow towards the gear box?? Sorry kinda new to all this.

thanks
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Old 06-08-2011
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You run the risk of overfilling it, plus it will be a huge PITA.

How is it stripped? Can you weld a nut on it, drill it out, drill and use an EZ out? There are alot of options to do it the right way, might be easier in the long run too.
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Old 06-08-2011
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Well its just rounded out... I have tried many things, hammer + chisel, jb welding an extension in it, basically it won't budge... I am worried about EZ out because of getting chips into the gear box.. I am not that experienced.

Now you said I run a risk of over flowing it, what if I fill it by the exact specifications? I have a heynes ford ranger manual (says it takes 2.5 quarts)
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Old 06-08-2011
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take the cover off and drill it out then no shaving in your gears.

don't risk filling it with not knowing the level you could blow your axle seals
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Old 06-08-2011
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Or just get a new cover with a fill and drain plug on it....
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Old 06-08-2011
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I have been searching for one of those but can't find it. I can only find the ones with a drain hole.
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Old 06-08-2011
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Old 06-08-2011
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thank you very much for the links danger, pretty expensive though and good idea.. welding a nut to the stock case, problem is I have no welder. I still don't see how filling through the breather hole is a problem if I just fill it to the specifications??
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Old 06-08-2011
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yeah they are spendy, but so awesome. lul.

Filling it through the vent hole will take forever, because its a small hole, and there is no vent for the displayed air to go.....but good luck. Also a high risk of overfilling, but if you've got the cover off and totally empty oil (remember there is some oil in the axle tubes), you're probably fine.....

And how the hell did you round the fill plug???
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Old 06-08-2011
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THIS IS WHY YOU DONT TRY TO REMOVE THE PLUG WITH AN EXTENSION!!!

numerous companies sell the proper tool to remove the fill plug
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Old 06-08-2011
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I fill mine through the ABS sensor hole on top of pumpkin. Holes bigger, and vertical so you don't spill.
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Old 06-09-2011
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So I filled it through the vent hole, it worked out fine but yeah.. it was a ***** and took forever. I filled it to 2.5 quarts (stated max amount in heynes book) and been driving on it.. no noise from the diff, everything feels fine.

As for how I stripped it. Well I didn't even use an extension, I just used a regular 3/8 ratchet head in there and it just wouldn't budge I pulled so hard it would slip and eventually rounded. Do they use loctite or some **** at the factory? Seriously it was impossible to budge.. even torched the bolt and jacked the truck up for better leverage.
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Old 06-09-2011
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you can fill it from the breather but make sure you put in the amount they specify. if you over fill it will blow the seals.

no need to jack the truck up.
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Old 06-09-2011
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Wirelessly posted

Ever hear of pb blaster
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Old 06-09-2011
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Quote:
Originally Posted by 04RangerDave View Post
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Ever hear of pb blaster
PB is for beginners and easy stuff, the blue wrench (or better yet an induction heater) is where it's at.....

I've seen OEM threadlocker or some type of sealant on almost all the plugs I've pulled. Best to heat before even trying on the firsttime from Ford.
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Old 06-12-2011
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Someone must have changed the diff fluid in my truck before I bought it because I got my fill plug out with a 3/8 wratchet. Just pulled real hard and out it came (oh man... that sounded BAD)....
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Old 06-12-2011
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^ nothing bad about being too tight. Not hot dog down the hall way
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Old 06-13-2011
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Heat around the fill plug then take an air hammer with a chisel bit and make a divot then angle the air hammer so it's hammering to spin it out. I have had to do this on cars that were already striped out. I would only do this if you are experienced or find some one that is. It is way faster than drilling. It also works on lug nuts that are rounded out.
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Old 06-13-2011
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^ nothing bad about being too tight. Not hot dog down the hall way
I lol'd
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