Stuck axle fill plug

[Chevyguy]

Well this being my 8'th Ford 8.8 rear I was bound to have one with a stuck fill plug..

Went to change the axle fluid in the 96 for my first time (That pesky engine swap ate up my free time last fall) and the plug seemed a bit wobbly the extension would not fit tight and flush like normal. Sprayed it down with PB blaster and tried to scrape out any debris but not really any better. Gave it a good try but the plug was stuck hard and the square drive stripped out quite nicely. I had loosened the cover bolts but had stopped short and said to self.. Better to remove the plug first just in case it's stuck...

I found out that an aftermarket differential cover can be fit to allow fliling the axle... Here is the cheapest I could find new it's cast IRON

http://www.knowwhere2jeep.com/solid-axle-heavy-duty-ford-8-8-differential-cover.html

This one is aluminum and has a drain plug too

http://m.summitracing.com/parts/GTA-40-2013AL

Ebay cheaper and has the preload bolts

http://www.ebay.com/itm/ws/eBayISAPI.dll?ViewItem&vxp=mtr&item=290618146937#ht_3715wt_11 81

Anyone run into this problem, seems like getting the cover is the easy way out. I would assume I could end up paying $100 just to get the plug removed

I changed out the Marauders rear a few months ago with nice Mobil 1 75W140 LS stuff was NOT CHEAP!! Went without a hitch

[babbage]

Take it off, drill and tap a new hole. Leave old one there.

Or just get an aluminum one from a P71 in the yard for $10 or whatever..

Or you could get a nice trick flow girdle for the MM (Like I have) then use the old MM cover on your 96..

I like option 3 the best.. :)

[Chevyguy]

Adding drain plug to the 96, that has an aluminum cover plus I have a spare in the cellar!!

So.. I will drill the spare cover seal it up with one of these drain plug kits.

http://www.autozone.com/autozone/accessories/Dorman-AutoGrade-universal-transmission-drain-plug-kit/_/N-25r9?itemIdentifier=149994&_requestid=657434



Not the 96 but you can see there is some nice spot there to put the "Fill plug" just gotta keep it away from the carrier

http://i348.photobucket.com/albums/q329/folingo/2001%20Crown%20Victoria/Dual%20Exhaust/P3260617.jpg

Compare to where the fill plug is in this cover

http://farm6.static.flickr.com/5142/5587877729_bbe1c4f370_o.jpg

[Siege]

If you know a good welder you could have them weld a bolt or socket to the fill plug. The heat from welding will free the fill plug easily.