I've finally completed rebuilding my rear suspension (top to bottom). The final thing I wanted to do was to change my differential 90wt, drained the old stuff, but cannot budge the filler plug. Does anyone have any tips for either getting the filler plug out or an alternative filling source? I could have sworn I saw a posting where someone had the same problem and received some advice for filling from an alternative opening???

 

I had the same problem. I used a propane torch to heat the cover to expand the aluminum which released the bind on the plug. But it was on the bench, far away from the gas tank!

 

The thought crossed my mind that heating it up might help, but I really hate to pull the dif. (darn!!). Good advice to heat it up off the car. If this is my only alternative, I might change it out for an R200 (what the heck)!!

 

I have used an open flame and did some welding under the car. I had it out of the garage and couldn't smell any gas fumes from the old girl so I was pretty sure I was safe. I had a fire extinguiser handy just in case. Heat it up around the plug as quickly as possible and turn off the flame. It only needs to get to about 200 degrees. Aluminum expands more and much faster than the steel plug.

 

I found it easier to just pull one of the half shafts. They just snap in. i filled mine when I was changing my springs. I had to pull the half shaft any ways.

 

I thought I saw that you could yank a half shaft and fill from there. I was going to pull the dif last night, but ended up across the street at my neighbor's barbeque. I'll try this first and see how it goes.

Thanks guys!!

 

Rather than pulling the differantial just pull the gas tank. I did it & it's easy. All you have to do is take the cap off in the trunk & drain the gass, then disconnect the hoses (from the hole in the trunk). There are 2 bolts holding the straps which hold the tank (its light). Once off then try the propain method previously suggested. I would rather do that then mess with pulling the whole differential. Oh, I pulled the tank (to clean) & it was easy.