BTR Diff Rear Cover Removal

[Badgerchim]

Hi. Whilst the diff (BTR) is off the car I am doing an external refurb and have found the drain plug is seized which I believe is quite common.

Rather than take take the whole diff, I thought I could take the cover to a friendly welder and get a big nut welded on but although the top of the cover has released the bottom doesn't want to release. Before I give it a bit more welly, I vaguely recall someone on here saying the drain plug locates into the diff casting and will have to be removed before the cover will come off. Or is it just stuck and tight on the locating pin

Please can somebody confirm



Ta very much

[phillpot]

Doesn't look that bad?



What you been using? I'd have thought a single hex socket would get a hold on that, and if not a decent quality pair of "Mole" grips?

[Sardonicus]

Old bi-hex socket you dont care to ruin and strike over the rounded part you have there the shock will loosen the threads and that plug will screw straight out , if you want to blow torch the plug 1st and allow to cool then this will only help , personally air hammer/chisel with a spike on straight onto the base of that flair bolts molded washer off in seconds

[jojackson4]

What Simon says
If still stuck weld a 17mm nut on it
And show it who’s boss

[Badgerchim]

Thanks chaps. I tried my normal socket and mole grips without success. I will invest in a bi-hex and give it a go before the 17mm welded nut method. Ta Tim

[Chimp871]

I'd be using a blow torch before paying brute force.

When these things finally come out they're like trophies to collect. At least I do

[Badgerchim]

Hoorah success. Bought a single hex socket and with a breaker bar it did the job.
Thanks all for the pointers.

[phillpot]

Badgerchim said:

Hoorah success. Bought a single hex socket and with a breaker bar it did the job.
Thanks all for the pointers.

phillpot said:

I'd have thought a single hex socket would get a hold on that