Wanted to change my front diff fluid last weekend and found the bolt rusty and seized. Tried a breaker but in awkward positon since I’m only using rhino ramps. I hate the Allen bolts. Worried I may round them off

Any suggest how to remove. Liquid Wrench?

HEAT! Map gas with a nice fancy tigger torch head

No offense intended if you already know this... be sure the FILL plug comes off before working on the DRAIN plug...

The first time I took my drain plug off, I had to use a bottle jack on the breaker bar. (Yes, I made sure it didn't get rounded off.) And mine wasn't even rusted. I assume the previous owner used a quick lube place, and they don't know what a torque wrench is.

Heat! The bolt should have a washer underneath it so all you need to do is heat the bolt and washer interface until the rust breaks.

As others have mentioned, a torch is necessary. Also grind the tip of your Allen key, or socket flat on the tip to get a better bite. I initially tried other suggestions I read on here of using a cold chisel on the outer edge of the plug to try to rotate/break it free, but until I broke out the torch, it was just making a mess of the plug and deforming it. Once I found the chisel wasn’t budging it, I promptly ordered a new replacement plug and put off doing the change until I had it in hand. The torch IS the answer, but I wouldn’t recommend propane as it won’t get it hot enough. You minimally need mapp gas, or better yet oxy/acetylene. Don’t reuse use the old plug and washer, just get a new one. Also, I added anti-seize lube to the replacement so hopefully it will come off next time without as much fanfare.

I rounded mine so I welded a nut onto it and was able to get it unthreaded. It took a couple tries to weld it on solidly so I think the heat from the weld really helped to free it.

Make sure the allen socket on the plug is clean all the way to the bottom, so the allen wrench will bottom out all the way. Take a hammer and tap the allen wrench into the plug as far as you can get it before applying torque. Also, if you are using an extension between the allen wrench and the breaker bar, support the breaker bar end solidly on a jack stand or something so the wrench doesn't go crooked and twist out of the plug.

In my experience, most rounding off is the result of a poorly fitting wrench and/or not enough care in making sure the wrench stays fully engaged with the plug.

Just rounded mine the other night. Bought a replacement plug, so I need to find a welder to weld the allen in there to break loose.

This kit;

https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

Got mine out. New plug with anti-seize on the threads. Shouldn’t be an issue in the future.

Derek V

Thanks everyone for your feedback. Will try those suggestions

ball peen hammer, chisel, 5 lb sledge. That's how I got my original one off. Tapped the hell out of the plug with the ball peen, then went to town with the 5lb and chisel. Eventually it started turning.