Diff drain plug

[zimtuff]

Ive run into some bother trying to remove the drain plug on the diff so I could change the oil(32000klm service requirement).
It feels as if the thread is damaged. It wasnt tight,in fact I was happy it was going to come out so easy but after a while I noticed the plug was not coming out of the hole.
I only used a socket and 12 inch rachet spanner to turn it,no breaker bars or extensions.
Ive tried tightening it up but now it just turns. No oil is leaking out but it is full as I checked it by removing the fill plug.

So what now? How can I get some sort of thread back in there ,helicoil perhaps?
How can I get the plug out? Ive tried pulling and turning it with some multigrips to see if I could get the thread to bite ,but no luck.

I cant imagine how this has happened. The last dealer to touch it at the 16000 klm service only had to check the level.
Assuming the plug has not been touched since new,could it have been faulty from the factory?
Ive done this dozens of times on my 4wds ,cars and other engines and never had this problem.

 

[Gothlander]

Maybe it has had a Helicoil fitted previously and its turning with the bolt or it has just grabbed the thread. Sometimes if you can find a way to apply outward force on the bolt while turning it may come out. In seeing the problems a lot of guy's are getting by changing the diff oil I wonder if it can be syringed out through the filler hole so as to leave the drain bolt in place.

 

[zimtuff]

Maybe it has had a Helicoil fitted previously and its turning with the bolt or it has just grabbed the thread.

Good point ,I hadnt thought of that.

Sometimes if you can find a way to apply outward force on the bolt while turning it may come out.

I had a half hearted attempt with some multigrips,I guess it will need something drilled in there for that to work.

In seeing the problems a lot of guy's are getting by changing the diff oil I wonder if it can be syringed out through the filler hole so as to leave the drain bolt in place.

I think it could using a tom thumb. I have one ,although I had planned on pumping oil in ,not out LOL.

I spoke to my dealer,he is willing to have a look but he is not sure if there enough metal to fit a helicoil. I cant get it in till next week so I may try another bike shop that does machining ect

 

[budman]

..syringe it out would be my method too at this point..

 

[MountainMan]

http://cgi.ebay.com/ebaymotors/Triu...7988200QQptZMotorcyclesQ5fPartsQ5fAccessories

Just in case the simple stuff doesn't work.

 

[zimtuff]

..syringe it out would be my method too at this point..

I could do that but I would really like it fixed properly.

Does anyone have a pic of the plug off the bike ,or any idea how much thread is on the plug?

 

[zimtuff]

http://cgi.ebay.com/ebaymotors/Triu...7988200QQptZMotorcyclesQ5fPartsQ5fAccessories

Just in case the simple stuff doesn't work.

Thanks GR,I had intended to look on ebay today. Ive sent them a request for a shipping price.

 

[Doc Roc]

You could try to drill and tap the plug so that you can put a bolt in it to get a slid hammer on it or just a bit of outwards force on it while undoing it.

 

[Blastedbones]

Gotta get that bolt out & get a new one..

 

[zimtuff]

Gotta get that bolt out & get a new one..

For the time being its holding the oil in. I dont have a helicoil gadget. I was considering pulling the bevel box off and giving it to someone who knows these things,unless they can do it in situ.

How much do you have to lift the bike the remove the rear wheel?