rear differential filler plug head rounded! please help....

[packinkimber45]

previous owner stripped bolt, one side of bolt came off, tried 15/16 socket and 24mm and it just strips it even more. any ideas how to get off. dont want to have to take off rear diff. thanks

 

[silver bullit]

Take the socket that fits the tightest and put a metal filter screen off a filter or a screen door layer it 1-3 layers. Put it on the bolt and push the socket so it lines up with the head of the bolt. Jam it so it sits on the bolt and in the socket. You may have to hammer light on it to fit. If that dont work try less layers on the metal screen or the next size socket. Or try using a breaker bar and tighten it and losin it about a 1/8 a turn or so back and forth a few times to see if that helps.

 

[2fast4]

Take the socket that fits the tightest and put a metal filter screen off a filter or a screen door layer it 1-3 layers. Put it on the bolt and push the socket so it lines up with the head of the bolt. Jam it so it sits on the bolt and in the socket. You may have to hammer light on it to fit. If that dont work try less layers on the metal screen or the next size socket. Or try using a breaker bar and tighten it and losin it about a 1/8 a turn or so back and forth a few times to see if that helps.

That's an one-off unorthodox way I'm having the same issue with *tranny drain* bolt. Same deal?

 

[silver bullit]

I did that to take striped bolts, nuts and plugs and it works.

 

[Defiant]

I've used the rounded punch-point of an air chisel in the past.

 

[MMM]

Welder. If you don't have one, drive to the nearest splash-and-go and have them weld a nut on the top of the old bolt. Works like a charm.

 

[packinkimber45]

Good new guys! Got the freaking bolt out finally, it's been a couple of weeks now since I fixed it. I just forgot to post how I fixed the problem. It's amazing what a monkey wrench (pipe wrench) can do. Yes that's right a pipe wrench. I tried to use a 23mm socket by driving it as hard as I can with a hammer, but I could not get it to work. Bolt became more rounded as I kept trying to use other methods. Finally I pounded on the stripped bolt with a large screw driver to leave a gouge in it for the pipe wrench to grip onto and it worked. Whole process took less than 2 minutes. I should have tried this the first time. I would have saved myself hours of swearing, sweating in the hot sun, frustration, and not too mention lots of cigarettes. Thanks for all the advice guys. Hopefully this will help someone else later. Woohoo! I guess I need to add a pipe wrench on my tool list.