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BigJimnyMeet (North) 2024 (12 Jan 2024)


BigJimnyMeet 2024

14th July 2024
Parkwood Nr. Leeds

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Diff Drain Plug Removal

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18 Jan 2018 15:35 #188522 by furo
Diff Drain Plug Removal was created by furo
Hi folks,

I am trying to replace my diff oil and have new drain and filler plugs from this site. I managed to change the front diff oil quite easily. For the rear diff I needed to use vice grips to undo the filler plug but I'm having no luck at all with the drain plug. The 10mm tool has really rounded off the hole and I can't get any purchase with my vice grips. Can anyone recommend any tips for removing it?

On a similar note I'm also having great difficulty replacing my panhard rods, any advice for seized bolts? I've tried extensive WD40ing and tapping with a hammer but to no avail.

Many thanks

2004 Jimny Mode: General Grabber AT3s (215/75/R15); Trailmaster 2" Lift; Jimnybits Snorkel; Jimnybits Front and Rear Recovery Points; Suntop Roof Rack; AVM Manual Hubs; Stainless Steel Exhaust System (SOLD)

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18 Jan 2018 15:54 #188523 by Mraz
Replied by Mraz on topic Diff Drain Plug Removal
Drain plug's best friend is a heat gun. Minute or two of heating it usually helps a lot.

As for seized bolts... use the force :) Or cut them and put new ones.

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18 Jan 2018 16:53 #188525 by jackonlyjack

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18 Jan 2018 20:39 #188545 by furo
Replied by furo on topic Diff Drain Plug Removal
Thanks for the help guys! Unfortunately I don't have a heat gun and can't weld. I have read about using a chisel but nothing in detail, how does that work?

I attacked the panhard rods with more force and managed to replace the rear one. Thanks for the words of wisdom Mraz haha! Unfortunately the front bolts weren't budging at all.

2004 Jimny Mode: General Grabber AT3s (215/75/R15); Trailmaster 2" Lift; Jimnybits Snorkel; Jimnybits Front and Rear Recovery Points; Suntop Roof Rack; AVM Manual Hubs; Stainless Steel Exhaust System (SOLD)

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18 Jan 2018 21:43 #188548 by Jimx5
Replied by Jimx5 on topic Diff Drain Plug Removal
No eBay APP ID and/or Cert ID defined in Kunena configuration

This is what you need, either e-bay or your local B&Q

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18 Jan 2018 23:43 #188549 by Busta
Replied by Busta on topic Diff Drain Plug Removal
Seeing as you have a replacement it should be easy enough to knock it undone with a chisel.

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19 Jan 2018 11:44 #188570 by furo
Replied by furo on topic Diff Drain Plug Removal
Thanks for the help guys!

Jimx5: that looks ideal, I'll pick one up today. In terms of safety are there any precautions I should take? How hot should the bolt get? Where do the fuel lines run? I'm not keen on exploding myself.

Busta: Great, thanks - I'll give that a go

2004 Jimny Mode: General Grabber AT3s (215/75/R15); Trailmaster 2" Lift; Jimnybits Snorkel; Jimnybits Front and Rear Recovery Points; Suntop Roof Rack; AVM Manual Hubs; Stainless Steel Exhaust System (SOLD)

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  • Lambert
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19 Jan 2018 12:15 #188572 by Lambert
Replied by Lambert on topic Diff Drain Plug Removal
Don't go mad with the heat, remember that you are trying to change the oil, which is sort of very flammable. Go gently.

Temeraire (2018 quasar grey automatic)
One of the last 200ish of the gen3s, probably.
ADOS Attention Deficit Ooooh Shiny!

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19 Jan 2018 12:22 #188573 by Jimx5
Replied by Jimx5 on topic Diff Drain Plug Removal
Don’t heat the plug, heat around the plug.

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19 Jan 2018 13:06 #188578 by furo
Replied by furo on topic Diff Drain Plug Removal
Thanks again, and sorry for all the questions.

And for the front panhard bolts as well - just gentle heating?

I went to B&Q in my lunch break and got a blowtorch and a chisel, looking forward to giving this a go!

2004 Jimny Mode: General Grabber AT3s (215/75/R15); Trailmaster 2" Lift; Jimnybits Snorkel; Jimnybits Front and Rear Recovery Points; Suntop Roof Rack; AVM Manual Hubs; Stainless Steel Exhaust System (SOLD)

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19 Jan 2018 13:36 #188579 by Lambert
Replied by Lambert on topic Diff Drain Plug Removal
Just to be absolutely clear, if you are not completely confident in what you are doing with the heat don't run the massive risk of burning your car down. Use a garage to loosen the bolt for you. Don't be a hero, be sensible and safety conscious.

Temeraire (2018 quasar grey automatic)
One of the last 200ish of the gen3s, probably.
ADOS Attention Deficit Ooooh Shiny!

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19 Jan 2018 13:51 #188580 by furo
Replied by furo on topic Diff Drain Plug Removal
Thank you, I appreciate the safety advice. I will be very cautious with the heat and I fully take responsibility for doing this.

I really enjoy learning and developing my skills so I am keen to try things out before taking it to a mechanic.

2004 Jimny Mode: General Grabber AT3s (215/75/R15); Trailmaster 2" Lift; Jimnybits Snorkel; Jimnybits Front and Rear Recovery Points; Suntop Roof Rack; AVM Manual Hubs; Stainless Steel Exhaust System (SOLD)
The following user(s) said Thank You: Lambert

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