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Rear diff plug disappeared wtf

Discussion in 'A4/S4 forum(B5 Chassis)' started by Ian2012, Feb 5, 2013.

  1. Ian2012
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    Ian2012 Active Member

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    [Feb 5, 2013]
    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
    #1
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  3. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [Feb 5, 2013]
    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 !!
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  4. Ian2012
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    Ian2012 Active Member

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    [Feb 5, 2013]
    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!!
    #3
  5. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [Feb 5, 2013]
    It does seam to sit quite flush iirc maybe its caked in **** and oil try blasting it of with a jet wash its there somewhere lol
    #4
  6. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Feb 6, 2013]
    its to the rear of the drive flange on the drivers side of the diff.

    Pic here:

    [​IMG]

    [​IMG]
    #5
  7. Ian2012
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    Ian2012 Active Member

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    [Feb 6, 2013]
    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??
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  8. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Feb 6, 2013]
    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?
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  9. Ian2012
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    Ian2012 Active Member

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    [Feb 6, 2013]
    if i had welding kit that would be the way forward, i will have another look and see if a chisel will work,
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  10. jimmcgee
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    jimmcgee Member

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    [Feb 6, 2013]
    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:
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  11. Ian2012
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    Ian2012 Active Member

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    [Feb 6, 2013]
    it would also be the rust spot then, lol
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  12. PAULF
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    PAULF Active Member

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    [Feb 7, 2013]
    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.
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  13. Ian2012
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    Ian2012 Active Member

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    [Feb 12, 2013]
    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.
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  14. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Feb 12, 2013]
    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.
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  15. boost-addict
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    boost-addict Active Member

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    [Feb 13, 2013]
    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?
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  16. Ian2012
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    Ian2012 Active Member

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    [Feb 13, 2013]
    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.
    #15

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