I rounded my head..help!!

[userj8670]

So i was trying to take my rear differential plug out the other night (the top one) to change the gear oil and it would not move for the life of me. Long story short i tried everything from breaker bar to impact wrench and in the process the head is now toast. Happened when i put the breaker bar to it and got pissed off at it. What do i do? I have never had this happen and i am sure i need to change my oil as its never been done since i have owned it.:confused: :confused:

Jim

[cybrman]

Go get some bolt extractors (kinda lock sockets) or some vise grips on it.

[Name Brand]

I'm sure Sears has the same thing, but these twist sockets work well.
http://buy1.snapon.com/catalog/item.asp?item_ID=65957&group_ID=11918

Maybe put a little heat on that cap first too. (WARM, not hot to the touch!)

[userj8670]

I have tried vice grips with no avail. I figured after about 3 seconds that if the breaker bar didnt work it lose the vice grips wont. As to those snap on sockets...i do have those and those were what rounded my head lol! Any other suggestions?

[DeePa]

heat the hell out of the plug and give it hell

[HuntingFor1]

Take a chisel or punch and carefully bust the top part off where the Oring is and you should be able to screw the threads out with your fingers.

[cr480r]

Weld a bigger nut or socket onto it...

[devilman]

autozone has a nice set to remove stripped/rounded heads. i think they are made by dewalt. i had to pull a bolt out of an 350x head that was rounded pretty bad, since they were so tight, a regular socket stripped it. the socket gripped very well and loosened it up.

[Jonpin]

I'm sure Sears has the same thing, but these twist sockets work well.
http://buy1.snapon.com/catalog/item.asp?item_ID=65957&group_ID=11918

Maybe put a little heat on that cap first too. (WARM, not hot to the touch!)

jesus tellin people to buy snap on is like telling someone "insert generic statment here " couldnt think of one, but yea you know you want them but they just cost to darn much all mine got taken from me when my storage shed got broke into during christmas "hopefully they get horrible diseases and die very slowly":twisted: took me a long time to save all those tools to just got a lil at a time at yard sales and trade craftsmen to ppl

[Dirtcrasher]

Take a chisel or punch and carefully bust the top part off where the Oring is and you should be able to screw the threads out with your fingers.


Exactly what I would do.... If this is the 17MM head 250SX or ES fill plug, they do it often. Always grease those threads and use a 6 point socket to remove the plug. It's real thin walled too, I've had them snap off.

Too much heat will toast the 3 axle and pinion seals so be aware of that....

[userj8670]

DC and Huntingfor1 i am a little confused here with what that means?

Jonpin- i know what you mean about snap on lol. You should see all the snap on tools the farmer across the street has. He has 4 tool chests full of every tool imaginable. If he doesnt have it, that tool was never made. Got to have like 3,000,000 in snap on tools alone! He is retired and restores tractors for fun now.

Jim

[userj8670]

p.s. It is the 17 MM sx fill plug. Sorry for not specifying

[Jonpin]

the problem i had was mine was tightend to much and cracked the lip on mine when i got it and had tan fluid in it im sure it was from water getting in i took it off and found a valve cover on some shitty chinese bike and it fit perfect it just tightens with a flat head instead of a socket now changed fluid twice now trying to get the fluid clear sure im going to have to do it again change it ride it change it ride it

[Erics350x]

weld an old socket to it and unscrew it while its still red hot

[Dirtcrasher]

It's an aluminum plug...

Get a chisel and whack it in the loosen direction on the outside diameter of the plug - further out, the more leverage.

[Jonpin]

you just have to soften that o ring up maby put some brake fluid around the o ring to eat it away probly wont work though idk

[HuntingFor1]

DC and Huntingfor1 i am a little confused here with what that means?

The cap has an Oring under it that is bad to stick to the cap itself and the gearcase. I have used chisels to "chip" off the outer edge of the cap where the Oring is stuck. Most of the time the cap will come on off before you get finished with knocking the outer edge of it off.

[Jonpin]

DC and Huntingfor1 i am a little confused here with what that means?

The cap has an Oring under it that is bad to stick to the cap itself and the gearcase. I have used chisels to "chip" off the outer edge of the cap where the Oring is stuck. Most of the time the cap will come on off before you get finished with knocking the outer edge of it off.

ok this is the best way i can explain what hes talking about "with pics :)"


heres is what the bottom looks like with the O ring
http://img117.imageshack.us/img117/1619/pict0221ft9.jpg (http://imageshack.us)
http://img117.imageshack.us/img117/1619/pict0221ft9.f998bc32ce.jpg (http://g.imageshack.us/g.php?h=117&i=pict0221ft9.jpg)

and heres the top mine is broken so you can see the area hes telling you to chistle away its to reliev the bond of the O ring ,in the end you will need a new cap for sure so this is a last resort method i would say "or just to prove a point to that *Edited**Edited**Edited**Edited**Edited**Edited**E dited* cap whos boss"
http://img149.imageshack.us/img149/1930/pict0223li9.jpg (http://imageshack.us)
http://img149.imageshack.us/img149/1930/pict0223li9.1950cb7571.jpg (http://g.imageshack.us/g.php?h=149&i=pict0223li9.jpg)

"couldnt resist digging that old cap up befor bed and taking pics and hosting them to help some one out" your welcome :)

[HuntingFor1]

Thanks Jonpin. I was going to do the same thing but I couldn't find the one I had to post pictures of.

[userj8670]

Hey guys,

I think i understand what you guys are saying but it sounds like your saying to chisel the head and o-ring area off but i would be reluctant to do that for fear of damaging the threads in the gearbox?? If you guys think nothing of this then i will go ahead but i wanted to double check and make sure. Also would an easy out work? Never thought of that before.

Jopin- thanks for the pics!! they ALWAYS help in a situation

Jim

[HuntingFor1]

The threads are in the gearbox so you shouldn't be close to them. Don't chisel the plug shraight on the top side but instead chisel it on the outer edge at an angle like in the picture below and chisel it like you are trying to unscrew the plug. Be sure you have a sharp chisel and don't use the biggest hammer you can find. Take your time with it and make sure your chisel isn't hitting the gearbox housing and you should have no problems. You will know you are deep enough on the edge when you can see the Oring. Once you can see the Oring enough to grab it with something you can try pulling it out and the plug may turn loose then. If it doesn't, keep chiseling the corner edge of the plug off. The plug will probably turn loose before you get finished chiseling all the way around it. Something else to watch out for is the little peices of metal that you chisel or break off. Be sure to keep the area around the plug clear of them before you take it out or they could fall into the gearcase.

[smvorndran]

I use an air chisel on a lot of stuck bolts, and it works 99% of the time. Don't go hog wild, and it will work loose in a few seconds.

smvorndran

[Name Brand]

jesus tellin people to buy snap on is like telling someone "insert generic statment here " couldnt think of one, but yea you know you want them but they just cost to darn much all mine got taken from me when my storage shed got broke into during christmas "hopefully they get horrible diseases and die very slowly":twisted: took me a long time to save all those tools to just got a lil at a time at yard sales and trade craftsmen to ppl

So... you're perturbed that my example of a tool to use is from a manufacturer that has a reputation for high quality? I used their website becuase it was easy to locate the tool and had a clear picture of it. I didn't tell anyone they had to buy Snap-on, I also said Sears has the same thing. When it comes to tools I'm not brand loyal; I've used a log to knock my suspension back into place before. I don't mean to sound angry; I'm really only confused by your run on sentence. :confused:



Now for something more useful,

Use a grinder (or even a file since it's Aluminum) to make a notch in the side of the cap. That will give a good spot to set a chisel if you're hammering on the cap to turn it.

[Jonpin]

So... you're perturbed that my example of a tool to use is from a manufacturer that has a reputation for high quality? I used their website becuase it was easy to locate the tool and had a clear picture of it. I didn't tell anyone they had to buy Snap-on, I also said Sears has the same thing. When it comes to tools I'm not brand loyal; I've used a log to knock my suspension back into place before. I don't mean to sound angry; I'm really only confused by your run on sentence. :confused:



Now for something more useful,

Use a grinder (or even a file since it's Aluminum) to make a notch in the side of the cap. That will give a good spot to set a chisel if you're hammering on the cap to turn it.

i wasnt perturbed in any way about your example of a tool i just thought my statment was funny sry you didnt and as for the run on sentence heres another one I love Snap-On just cant realy afford it i dont know if its just a mental thing but everything seems to go better when you use there high quality tools and I had to throw my lil story of my misfortune in there because im reminded about it every time i think about Snap-On and this will conclude my run on sentence .

[userj8670]

Thanks so much guys! I am going to try it out tomorow and we'll see how it goes. If that fails i might try to square the bolt off and see if i can then get a wrench on it. I will post later tomorow with my hopeful results.

:beer

Jim

[HuntingFor1]

Did you have any luck?

[userj8670]

didnt try it yet. farm work has prevented me from doing anything. barely have time to change my underwear ha! Hopefully soon though. would the dealer have a new cap for me...since i plan on destroyin the old one?

Jim


p.s. thanks for the follow up