Diff level plugs

Why is it always the same - I get a Suzuki second hand and I can never get the level plugs off to check the diff oil level. They have either never been checked for years so are almost welded in place or have been checked and whacked up tight by a really strong garage mechanic.

Even when new (and I have had precious few of those) some of the screws are so tight it's unbelievable.

Does anyone have any hints please before I put the impact air wrench to work? The front one already looks like a torx socket and I haven't even been near that yet.

The diff and gearbox/tbox plugs are all 10mm square drive

You can use a 3/8 ratchet head but be careful not to round the holes!

Heat it up a little

adamatdraycott wrote: The diff and gearbox/tbox plugs are all 10mm square drive

You can use a 3/8 ratchet head but be careful not to round the holes!

I started to use a 3/8 extension bar but it was beginning to turn so I stopped before I rounded it. I have a 10mm sump plug head but it was starting to turn too.

Heat it up a little

I did think of that - I always reach for the blowtorch in the end but I am tempted to try to drift it round with a chisel first.

Why are they always done up so tight, arghhhhhh. I have the front to do after and it is in a mangled state already. If these are this bad I am dreading the transfer box.

Mine came out easy with a few taps from a chisel.
Then I got the welder to it and fixed it up good

facade wrote: Mine came out easy with a few taps from a chisel.
Then I got the welder to it and fixed it up good

It's a nice fix, I'll try it if I can get the *****out - looks like the chisel tomoz.

Or grind a few flats on the plug!!

kirkynut wrote: I use a large set of Mole grips round the outside edge. This is now my usual way of undoing them. I don't do them up too tight (those that know me well may suggest I do not have the ability to under tighten things) and still they won't undo without rounding.

One day I'll get a nut welded on one but I fear that will lead to me over tightening them!

Kirkynut

I tried molegrips, I have a tube set that have curved jaws but no luck even when whacking with a hammer. I tried a chisel and still nothing. In the end it may have been a combination of those plus a little heat because in fairness the blowtorch was what did it. The front one was butchered before I even started on it. Also, I have ground a small pair of flats to get an adjustable spanner on them or just get a better grip with the molegrips. I doubt I'll need them next time because I tend not to overtighten things - things like these anyway - but like you say they somehow seem to get stuck regardless.

One motor I had simply had a bung! Can't remember what it was, it might have been a Jeep.

I fully expected to find dirty old oil in there but it was good stuff and was nicely topped.

Thanks for the help everyone.