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740 REAR AXLE FILLER PLUG - STRIPPED HEXAGON 700

The rear axle filler plug on my 1989 740 is seized and the hexagon has stripped in my attempts to undo it.
Can anyone suggest a way to undo the plug?

Mike Walker
London
UK








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    740 REAR AXLE FILLER PLUG - STRIPPED HEXAGON 700

    I went through this myself a few months back. I started drilling progressively larger holes down through the center of it, intending to use an easy-out once the the hole was large enough that the bolt head would fall off. But once the hole was large enough that the head fell off, I found that the load on the threads was reduced to the point that I could use a hammer and chisel to rotate the remains of the bolt counter-clockwise and it unscrewed quite easily.








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    740 REAR AXLE FILLER PLUG - STRIPPED HEXAGON 700

    I'm not familiar with the 740 rear axle and its plugs but if it has
    a protruding head, can you not use a pipe (Stillson) wrench? Once you
    get it out you can get a new plug and maybe a round or two of teflon
    antiseize tape will keep it from getting that bad again.
    --
    George Downs, Bartlesville, Oklahoma, Central US








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    740 REAR AXLE FILLER PLUG - STRIPPED HEXAGON 700

    I guess this must have an internal hex?

    Take a square handled cold chisel that has a blade width slightly wider then the longest dimension though the middle of the hex. File the sides of the cold chisel on a slant so that you get two sharp edges that will bite into the hex when you turn it counterclockwise. File the cold chisel sides just enough so that you can drive it into the hex with a hammer. Grip with a wrench and turn it out.








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      740 REAR AXLE FILLER PLUG - STRIPPED HEXAGON 700

      This is exactly what happened to me when I tried to replace the oil in my rear diff. I tried heating it up but nothing worked. I ended up taking the vehicle and the oil to my mechanic who removed the bolt using his torch.








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      740 REAR AXLE FILLER PLUG - STRIPPED HEXAGON 700

      JimL
      Thanks, but its an EXTERNAL hexagon
      Mike








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        740 REAR AXLE FILLER PLUG - STRIPPED HEXAGON 700

        Use a pipe wrench on it.

        Heating it with a heat gun or propane torch (be careful) may help loosen it.








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    740 REAR AXLE FILLER PLUG - STRIPPED HEXAGON 700

    One thing I did learn along time ago, if you are going to drain anything. Make sure where ever the filler is, you can get that off first.








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      740 REAR AXLE FILLER PLUG - STRIPPED HEXAGON 700

      Thanks

      I am not intending to drain the rear axle.

      I just want to remove the filler plug to check if it needs topping up.

      Mike








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        After you go through... 700

        all that work to get the filler plug out, you might as well drain and refil it. Unless of course you've done this very recently. Just my $.02

        Blue760t








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    740 REAR AXLE FILLER PLUG - STRIPPED HEXAGON 700

    Very important to use six-point sockets on seized nuts. Can you file off the rounded corners enough to get a six point on it? If you have to file down one socket size, do it.
    Other tips:
    -Heat it with a torch, then when it has cooled somewhat spray quality penetrating oil on it. Spray over a couple of days to allow penetration.
    -Cool it with electronics freeze spray to shrink it, then spray immediately with penetrating oil.

    Use antiseize on reinstallation, as this area receives lots of road salt.







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