So yesterday I attempted to change the rear differential fluid on my 15 Forester for the first time, at 85k miles.
So, I ordered the appropriate hex/torx socket attachments, etc. and watched a bunch of YouTube videos, read a bunch of forum posts, and felt ready. What I was not ready for, however, was six years of corrosion and pressure making the fill plug impossible to move. I got the 10mm hex on there with an extension and a cheater bar and gave it my all, but could not get the **** thing to budge. I read all sorts of helpful forum posts on ways to get the stuck plug out, and went outside to try them today. However, it seems that I inadvertently rounded the fill plug. So now I’m stuck.
This just adds to the problem, and the most popular way of dealing with it seems to be to weld a bit on the end of the bolt, which I am unequipped to do. I feel like I have come up with a workable solution, though, and thought I’d run it by the folks here to confirm that it is not a totally idiotic idea.
Basically, what I’m thinking is that I will take off the rear differential cover, thus draining it of old fluid. While the cover is off, I will either: a) try to use a grabbit, or some other sort of stripped fastener remover, to get to the plug, or plugs, out. Or, b) drill a new hole, and tap that to make a new fill plug.
If either of these failed to work, I would simply go to the dealership down the road, and buy a new differential cover. Even purchasing a new cover, with new plugs/gaskets, the hex sockets, and gear oil will be cheaper than having the dealer do the change for me.
Is this a reasonable course of action, or am I missing something? Thanks for your help
So, I ordered the appropriate hex/torx socket attachments, etc. and watched a bunch of YouTube videos, read a bunch of forum posts, and felt ready. What I was not ready for, however, was six years of corrosion and pressure making the fill plug impossible to move. I got the 10mm hex on there with an extension and a cheater bar and gave it my all, but could not get the **** thing to budge. I read all sorts of helpful forum posts on ways to get the stuck plug out, and went outside to try them today. However, it seems that I inadvertently rounded the fill plug. So now I’m stuck.
This just adds to the problem, and the most popular way of dealing with it seems to be to weld a bit on the end of the bolt, which I am unequipped to do. I feel like I have come up with a workable solution, though, and thought I’d run it by the folks here to confirm that it is not a totally idiotic idea.
Basically, what I’m thinking is that I will take off the rear differential cover, thus draining it of old fluid. While the cover is off, I will either: a) try to use a grabbit, or some other sort of stripped fastener remover, to get to the plug, or plugs, out. Or, b) drill a new hole, and tap that to make a new fill plug.
If either of these failed to work, I would simply go to the dealership down the road, and buy a new differential cover. Even purchasing a new cover, with new plugs/gaskets, the hex sockets, and gear oil will be cheaper than having the dealer do the change for me.
Is this a reasonable course of action, or am I missing something? Thanks for your help
