Rear end problem

[1937pickup]

Went to change the oil in my 37 pick up's rear end. As my luck would have it the drain plug rounded out, one of those 3/8 inch socket type. Anyone have ideas on how to get this out? I am thinking of trying CRC's Freeze-out. I know Kroil and 50/50 ATF and acetone are supposed to be the best, but I have tried both with no luck. I am thinking about tacking a nut to the plug as is done with a broken stud. Any one try this to get the plug out? I really don't want to pull the rear end.

Thanks.

[flatford8]

I'd clean it real well and then weld a piece of 3/8'' square stock in the hole. let it cool and then give it a try.....Mark

[SofaKing]

I am thinking about tacking a nut to the plug as is done with a broken stud. Any one try this to get the plug out?

Yes, I used a bolt, it worked. My axel was out of the car and bone dry inside so fire hazards from lube, fuel tank and burning of paper shim/gasket was not a concern.

[19Fordy]

As a last resort you could drill it out a little at a time until you almost reach the root dia. Then use a cape chisel to collapse it and pry it out.

[Alaska Jim]

heat it up ( the plug only) until cherry red with a torch wait until it cools down and then give it a couple of wacks with a hammer to "jar" things loose then drive a 10mm square socket into the hole. It should come out. there are specific square sockets of several sizes, both standard and metric just for these plugs. the 3/8 and 1/2 inch ratchets and extensions are not really made for this, but unless they are real tight they usually work.

[GEOFFNZ]

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Somtimes there is enough plug protruding from the housing to get a pipe wrench on the outside of it. Cheers

[Graeme / New Zealand]

If there's enough protruding - vice grips

GB

[FlatheadTed]

Pipe wrench X2 .Also use a big coll chisel and small dumpy hammer make a cut on the edge and drive it around , you will likely destroy it but ,I personally wouldn't use heat ,its likely just tight and will have oil residue on the threads ,You may be able to replace it with a plumbers Galv plug .

[Terry,OH]

http://www.fordbarn.com/forum/attach...1&d=1398707373
The square tang on the end of the adjustable wrench is what is used to remove the plug. The square is not 3/8 drive.

[Mart]

If you get a 1/2" allen bolt or other suitable piece of material and grind or file carefully until it just fits in, you might be able to use that to turn it.

[Planojc]

I have replaced all female plugs with male plugs for this reason.

[1937pickup]

Thanks for all the hints/help with this problem. I am going to try several and let you know.

[JM 35 Sedan]

X2 what Terry and Mart told you. A 3/8" square will round out that plug hole. Get or make something that has the correct size square for that hole, and leverage that plug out. Maybe even consider using the proper size square piece in a hand held impact driver. Using the old flame wrench on that plug or the area around the plug sounds like a train wreck waiting to happen.

[Alaska Jim]

you can use the torch with no problems, if you use care. I had to do this many times over the last 20 years working on heavy equipment. you can also get by with a propane torch, but you will not be able to make it red hot so just get it good and hot. what you are trying to do by heating up the plug and then letting it cool is to get the plug to expand, albeit a small amount, then when it cools it helps to break loose the rust and crud that may be helping to hold the plug in. it also helps to release the tension (torque) on the plug. the key is not to get it to hot if using a torch, and to keep the flame on the plug only, you do not want to heat the whole housing. the best way to avoid this problem is once the old one is out, throw it away buy a new one and use the correct tool , not a 3/8 or 1/2 Inch ratchet. those work, and many have used them for eons, but you have to use care not to over tighten them, or you are back to the same problem