Thread: Plastic Diff Plug Removal

Well, as you have the new brass 1s and the plastic fantastic is rendered useless by the slot rounding out I would just take my trusty cold chisel and large hammer and proceed! Try to hit the edge so as to turn them out but dont worry if you split them! Just dont burr the diff thread up!
Cheers Scott

I thought the slot was purely decorative

The plastic plugs are pretty much disposable - I try to have a spare or two on hand when I do the diff fluids. Can't remember which it is but a 21 or 22mm socket should fit. Failing that Scotts advice is the way to go.

cheers
Paul

I reckon your "first inclination" is on the money...depending on how solidly it is sealed, you might try drilling in about 7mm with the correct size bit for the largest 'easy-out' available to get better "bite". BTW you need something with a LH, not RH thread. The pitch on a LH threaded bolt however may not get sufficient purchase and will just cause the plastic to deform ...then it will just turn in the hole with no torque on the plug. A set of easyouts can be had for a few $. at the usual outlets.

This method i use for small plastic screws but should work the same.

Heat the tip of a large flat blade screwdriver and melt it into the plug.
Remove screw driver and let the plug cool.
Then you should have enough bite to undo it

Forget the screwdriver slot, a 21mm socket is the way to go. Unless that is also rounded. Then its chisel time.