Anybody else had a failure of their various plugs? I've just tightened up my rear diff fill/level plug, and it failed long before it even got tight, splitting in two. It wasn't the thread that failed, but the outer part that stops it going in deeper. Thankfully I was able to extract it. It was part # 5133736 (for benefit of peeps searching in the future for the same part #!).
I'm going to buy another torque wrench just in case my existing one is not working properly, but it worked just fine on all the other plugs so I don't think it's that. Just a duff plug.
On reflection, I think the fact that some diff oil leaked onto the thread didn't help - but I'm surprised people don't break them more often as I would consider that not an uncommon situation.
Just got mine back from it's second service. The little allen socket plugs were all changed to an ORB plug with a 1/2 inch head. I didn't like how the lowest one was so long so I cut half of it off which left lots to get a wrench on still. You do have to be careful thought the housings are fairly soft and can stip out easily. With the o-ring plug you don't need to have them too awfully tight. I know you don't what it to fall out either. Like fanjules says use a good quality torque wrench.
Still waiting for my plug. I got so bored I've ordered one from the US too along with a spare belt - going to see who can delivered fastest! It's almost as if I need TWO rzrs to satisfy my needs... hmmm, I need a bigger house and enthusiastic offroad girlfriend first though. A tall order on both counts!
Well, into the third week waiting for this now. Seems silly how something so small can render it out of action - so how about this for a temporary solution:
* use plumbers ptfe tape on the thread of the (now capless) plug, using enough to get a reasonable amount of torque to hold it still
* mark the plug to check if it has came loose (arguably you should do this anyway)
The tape should seal it, and if I use enough I should be able to get it to stay put, doing an initial test run to be sure it's safe. My only concern is that the rear diff will get hot enough to melt the PTFE tape, but since they use this in hot water and central heating it should be okay - anybody know if the diff runs partiuclary hot? I'm guessing it doesn't since it's a straight diff.
Is there no hydrualic shops near by? Thread tape is good for more temp than your diff should ever run but I wouldn't trust it and more is not better. I just reread your first post and it's your filler plug not the drain plug like mine. I don't know what size thread it is but a hydrualic or truck shop, lorrie I think you call them, should have something close. Good luck.
I tried it anyway, and it didn't come loose and it didn't leak - so a result!
I did search in various places but with no luck, in any case after waiting all this time it turns out my replacement plug is coming tomorrow! Had I known I wouldn't have tried my plumbers tape experiment, but that's sods law.
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