Rear diff plug disappeared wtf

[Ian2012]

So i am under the car today (see other thread) and i have diff seal that's gone maybe both sides, so i am looking for the filler to tpo it off for now, i am no stranger to quattro's btw, so i look on the left side hmm not there i look on the right side hmm not there either, i look again on the right side (drivers) and have scrape around nothing it looks like at some point and this is a guess some one has sheared a tool in the plug and it's now rusted flush with the casing.

Suggestions as to how to fill the diff please

Ta

Ian

 

[Bradderz_1988]

I used an air chisel with a very fine point tip to just shock the old one loose i re-used mine as it wasnt rounded but if yours is fubar then id order one from stealers !!

 

[Ian2012]

but there is nothing to get a hold on like it no evidence of a plug being there really odd i must say, unless of course i am blind!!

 

[Bradderz_1988]

It does seam to sit quite flush iirc maybe its caked in crap and oil try blasting it of with a jet wash its there somewhere lol

 

[aragorn]

its to the rear of the drive flange on the drivers side of the diff.

Pic here:

 

[Ian2012]

Thanks for the location pics, looks like mine is rusted and full of broken tool that is now flush with the casing, i suppose the only way to get oil in it is when doing the oil seal??

 

[aragorn]

i tried to fill mine thru the driveshaft hole, and just ended up covered in oil.

air chisel like bradderz suggests, or perhaps welding a bolt on might get you somewhere?

 

[Ian2012]

if i had welding kit that would be the way forward, i will have another look and see if a chisel will work,

 

[jimmcgee]

right , I know this sounds daft , but that casing is alu , so get yourself a magnet , and when it sticks to the case somewere like in that picture , you have found your metal plug :icon_thumright:

 

[Ian2012]

it would also be the rust spot then, lol

 

[PAULF]

Depending on your acces to tooling (such as a right angle drill)

Drill into the broken tool, screw in a hefty self tapper and lever it out to remove the tool?
Drill into the broken tool and use a DECENT 'easy-out' to remove plug and tool together?

Another method is to buy another plug, then drill two 1/8" - 3/16" holes into the plug and knock in two pins (such as phillips screwdriver shafts) you can then put a bar between them and unscrew the plug and tool.

 

[Ian2012]

Diff plug was full of rust and cack, cleaned it all out to find it's so rusted as there is nothing for any kind of tool to get a grip on, tried chisel and hammer, no joy with that. so i am looking a nut weld job or maybe drill the centre out a bit tap it and pop a bolt in with a sealing washer.

 

[aragorn]

just get a bolt welded onto it, M10 or M12 bolt will fit into the rounded out hole, blast of weld to secure it and the heat should break it free as well.

 

[boost-addict]

what oil are you using, and do you sugest using molyslip, its like a sealent for slow leaking diff seals, wondered if this runins any thing?
whats the best oil i can use?

 

[Ian2012]

The correct grade is 75w90, some folks use semi synth some use fully, personally i wouldn't run molyslip but i would use millers oils stop leak, so when i get the damn plug out i will be popping some of that in after doing both drive shaft seals.