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Stuck plugs on 2 different differentials.... easy fill through speedo sensor though?

posted by  Will740turbo on  Wed Sep 21 02:34 CST 2022
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last visit: Wed Oct 22 16:09 CST 2014
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I pulled a 4.10 axle off my 89 745 GLE to put on my 90 744 GL (also 4.10)

Aaaaand I tried to make sure I at least topped off the oil in the replacement one, but the fill bolt is quite stuck and both were quite mangled. I put some in through the speedometer/ABS sensor port. It's at about the same height as the fill plug. Both plugs were already damaged by previous attempts to remove them before me, and despite using a torch on the axle that was not installed in any vehicle, I couldn't get it to budge.

Anyway, it seems like there is a steel plug and a copper washer and an aluminum cover. Maybe it would be best to use plastic washers if possible.

The speedo/ABS sensor has a single 5mm hex/allen bolt holding it in. Make sure you use brake cleaner and/or a brush and soapy water to clean off all around the sensor before removing it. There is a sealing O-ring on the sensor. Make sure it is lubricated before installing.








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    Stuck plugs on 2 different differentials.... easy fill through speedo sensor though?

    posted by  Blindboy on  Thu Sep 22 20:10 CST 2022
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    last visit: Tue Oct 21 17:56 CST 2014
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    I took my 940 into the sho[p cause I couldnt get the plug off,,My mechanic heated it w a torch till it was red,,,got it off & I went to napa for a new one to put of w anti seize..But now Im wondering if there needs to be a better seal on the sensor plud or is it just the plate that leaks..I bought a new rear gasket & before I install it Ill coat each side w silicon sealant to provide extra sealant,,&& Ill put spring washers on each bolt..
    come to think about it,,If the fill plug is stuck it must because the lube leaked below it.?







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      Stuck plugs on 2 different differentials.... easy fill through speedo sensor though?

      posted by  Will740turbo on  Sun Sep 25 03:51 CST 2022
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      last visit: Wed Oct 22 16:09 CST 2014
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      I think they stick because of galvanic corrosion... in this case, aluminum diff cover, steel plug, and copper washer. Copper and aluminum shouldn't be in contact with each other. Plastic would be much more resistant, but an aluminum washer would be better than copper, I think.

      I don't think the oil level has anything to do with it, but maybe?







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