Rear diff filler plug.

[rob381]

Hi guys, i have an 04 plate gv 5 door and i have been trying to remove the filler plug on the back axle to change the oil. The previous owner must have used threadlock when it was put back in because it now will not budge. The small key that goes in the middle has rounded and i have tired hammering in an oversized torx bit but that just spins as well,even a hammer and chisel will not shift it. I wonder if any body else out there has had this problem and any advice as to how to get it out would be much appreciated. Thanks guys.

[ScottieJ]

welding a nut or bolt to it often does the trick, sounds like it's going to need to be replaced anyway.

[vitara_mad]

weld a nut onto the filler plug

[rob381]

Thanks for the advice guys, is a new plug a dealer part ? What's your thoughts on disconnecting the battery while welding a nut onto the plug and i am a little bit wary about welding near the fuel tank or is this me being over cautious ? Any way if this is the soloution then onward. Thanks guys.

[timwilks13]

when i did the welding in the engine bay i wrapped a wet cloth over the fuel lines to be safe, should be ok with the fuel tank as they're a bit more solid, maybe protect the fuel lines to be on the safe side.

[rob381]

thanks for the advice.

[timwilks13]

and always disconnect your battery when welding!

[Hodgie812]

If you are struggling welding the edges of a nut to the filler plug, weld a washer on first through the hole in the centre. This gives you a bigger surface area to weld a larger nut to. Also if you fill the key hole in the plug with weld once it cools its should shrink and make the plug easier to remove.
Jamie.