Rear Diff Cover, Mag-Hytek Bottom Plug froze, broke allen head clean off, was able to get it out.

Though, I've change fluid twice in it before, and it works great. This time, she won't budge, the top plug was a pia also, but it came loose eventually after some heat.

I use antisieze everytime, I mean I coat that thing that crazy, and its still locked up.

I ended up taking the cover off to drain the fluid.

Anyone have any ideas to getting that bottom plug off??

Why didn't Mag-Hytek plug a bigger plug head in it I have no idea. just plain dumb grrrr.

 

You probably over tightened it. I use to do same! With their thread design and o-ring, it really requires very little pressure.
I did same as you with a cheap allen head socket set once. It broke off but vibrated loose after two days of driving around. I also stripped the plug hole once by not being able to get allen wrench all the way in the hole (dirty).
Had to order a new plug from Jerry at Mag Hy-Tec and learned my lesson about tightening too far! Never used or needed anti seeze... enough oil on the threads to do the job, when plug is installed normally.

I agree that a redesign to take a socket would be great, but would not want it extending below the pan! A little recess woud be nice!

I could not get mine out either. Took the pan to a friends shop.... picked it up a hr later. He said it took a specialized tool but I did not see what he used...sorry.

Good luck!

RJ

 

I'm thinking the same, just to tight. I've been searching, and it seems you snug them, not tighten them.

How did you get your plug out? Heat? I read you have to drill and use a
punch to counter-rotate hammer it out.

I'm guessing I'm in for another plug, both top and bottom. I think I might have rounded the top inside threads. Had to use a vise grip...

 

See edit above.....and .... been there and done that!

For me it was a learning process... being the first time I ever had a drain plug in a differential, or a tranny. Tendency is to go too tight... but trust the designers and just do snug, like you say!

RJ

 

same thing happened to me on tranny and rear end cover. i ended up taking the diff cover to a machine shop and having a nut welded onto it.

 

SS plugs in aluminum will stick so it really dont matter if you over tightend it. Anytime you want to take one of the plugs out give the plug a good whack with a hammer, I mean a good solid smack but not hard enough to damage anything and it should come right out with very little effort.

 

BigBully I owe you a 12 pack.

You guys won't believe this, I went out there, hit the bottom plug twice.

Took a new socket allen wrench head and it turned! OMG I thought, like some dang magic trick, after all that cussn. Would you believe it!!

Post this one as a sticky, man you just saved my cover.

Now I'm gonna order a new fill plug, everything else is good to go.

I snugged it, not tightened it, every oil change I'm gonna check it.

thanks man, and DTR, wow... what do ya know some days....

 

LOL glad to help