Xel

I hate itt when any automaker uses an allen type of bolts. So plugs are rusted to sh8t and now rounded inside. Do I drill them out or something? It's pretty hard to access them underneath the car and I don't feel like taking the whole differential out to work on it. The diff fluid must be changed asap. Please help :-)

Anyone has part #'s for differential plugs btw?

I guess I am going to try to drill and use extractors to get these plugs out. Stupid engineers.

chefbob

can you weld a nut to it?

520

I never understood why are they superior to regular ones. I see nowadays they like using torx even more - even more trouble!

Anyone wanna chime in?

Xel

cant weld

chefbob

I wouldn't drill it out for fear of getting metal in there

dtompsett

Everyone warns to check the fill plug before you drain it... my fill plug came out easily, but the drain plug was stuck.... used a small torch on it to warm it up, tapped it with a hammer, and got it out.

I'd be afraid of damaging the diff housing.... but have you tried using a larger size hex on it? I stripped the standard 6mm 6-point hex on one of the main driveshaft bolts.... ended up using a 1/4" hex, hammered it in, and got the bolt out...... darn loc-tite red on the bolts. Oh... btw... those bolts are m8x48mm.... dealership didn't have any, but an m8x50mm works just fine, and can be found at most nut/bolt hardware stores (industrial supply stores). The extra 2mm isn't gonna throw the balance of the driveshaft off by much.... and if your really concerned, you can grind the end down a bit.

Ya, it really helps to have the hex-head sockets.... they are much nicer to use than allen keys.

OWDLVR

Wanna do the seals on my spare diff?

:-)

-Dave

nuugen

<center><img src="http://www.hazet.de/images/hits/2567-16.jpg"></center><p>The new plugs are a triple square tamper proof, and require a special socket to get them out---which are 70 bucks!! However Hazet makes one for~26.00, I ordered mine a couple months ago and had the dealer get me the plugs...I had to do some serious research b/c all the stealer kept telling me was that the old plugs were NLA and they didn't have the replacement # (even though all the new trannies/diffs have them installed from the factory what gives)...Finally got the number, thanks to PERL from the 'tex, and gave them the # to order---4.68ea, so I got several of them and did all 3 of my quattros...
2: I used an air chisel to take my old stripped plugs out of the 90q, my other cars' plugs were fine but the PO of the 90q had apparently stripped these...I have used an air chisel on several bolts/plugs of this type when they wouldn't come out normally, just gotta be careful not to cut through the bolt or plug and into the tranny/diff case---use a dull or blunt chisel..
I will see if I can track down the receipt for the part# of the new plugs...The tamper-proof socket is part# 2567-16, and you can see it and even view a video of the tool in action at: http://www.hazet.de/eng/index.htm...<ul><li><a href="http://www.hazet.de/eng/index.htm">Hazet Tools</a></li></ul>

nuugen

LOL I guess they came out w/the new tool/tamperproof plug to stop all the tranny-fluid theft !!

rabbid

Welded arc welded a socket into the stripped drain plug. The heat of the welding made it break loose pretty easy.

Then I contacted Chris at Force5 and he sold me replacement old school plugs for 5 bucks.