Sometimes you need to get in there with an impact driver to break it loose. The type you put a bit on, and hit the other end with a hammer.

Other times you have to get in with an air hammer, and a blunt ended bit to send enough vibrations to break it loose.

Last but not least, using a real torch - put some heat on it. I don't recommend using the simple propane torch for sweating fittings, since it takes too long to heat, and will get too many things hot, compared to Oxy/Acetylene that is hot and focused.

If none of that works, weld a bolt on the end. Good luck.

 

Best break out the vise grips.
1:Try heating the plug with a propane torch and quenching it with cold water. 2ON'T Drill it.
3:If it still doesn't come out, buy a replacement plug. Weld a nut to the stripped one, quench with cold water immediatly after welding and remove...

Good luck, F-Bombs help

 

If you have one or a friend, an old time impact driver to hit with a hammer they usaly have a Phillips or straight blade screw driver bit but you can take the bit holder off and it's like a ratchet drive either 3/8 or 1/2 " drive put an extension and a allen socket then smack the hell out of it. They twist when hit. I've gotten some pretty touph screws out before. Good luck

 

You can also take a ball peen hammer and tap the head of the plug. Also can run and warn up the whole gear box. Expands the case and will tend to loosing the plug. Do not install and tighten when the case is hot. Let it cool first.

 

Thanks guys for the suggestions. I have an impact driver. Guess I just need to head to Lowes and get and Allen wrench socket for it. All I have is standard Allen wrenches. I need something to plug into my impact wrench.

 

One thing I found out with my crankcase plug is make sure you have the bit or Allen wrench bottomed out in the plug.

 

In a pinch if you don't mind sacrificing an Allen wrench, cut about a 2 inch peice (yes tool steel is a bitch to cut) and put it inside the right size socket for your impact wrench. Heat up the plug and tap in the piece of Allen wrench to bottom out in the plug, slide the socket over it and impact it loose.

 

I feel your pain. Just changed the front and rear fluids on my 900s and had to use an impact to get them out. I think it's crazy they torque them on that much from the factory when I believe the manual says 12lbs.

 

I just use a 1/2" breaker bar and make sure the bit is bottomed out in the plug and you have everything lined up nice and straight, it will pop loose with a snap sound but it will come loose that way.

 

When you finally get it out, replace it with a new plug because it will be stripped, install the new plug with a small amount of anti-seize. If the impact doesn't work you might have to drill it and use a EZ out.

 

Think about it, heating the plug will make it expand don't heat plug, heat the case, gently. Aluminum expands at a much greater rate than steel and a small amount of heat will help. I ended up welding a nut on my plug after removing. Buying a new $28 plug just to go through this again is a little crazy. If you tighten the plug in warm ambient temps and then try to remove when it's cooler it can be problematic.

 

I'm heading to Lowes at lunch today. I'm going to find something cold in spray form I can spray on the bolt. Also going to buy an 8mm socket head. After spraying the bolt with liquid cold, I'm going to smack it with a hammer once then use my impact driver. If that don't work I don't know what will.

Thanks again for the advice guys.

 

One more trick

If you can get a Dremel in there you can cut a notch and use an oversized standard head screw driver. With an impact drive or ??

 

Chisel and a hammer. Hit the outer edge in the direction you want it to go (left). I destroyed one on my 800, but found an 16mm x 1.50 hex head plug at Orshcheln farm store. I put the allen head plug on the bottom, and the new longer plug it the side. Took all freaking day to change 7 oz. of oil. The F bombs didn't help, but I used a years worth that day!!

 

Chisel and a hammer. Hit the outer edge in the direction you want it to go (left). I destroyed one on my 800, but found an 18mm x 1.50 hex head plug at Orshcheln farm store. I put the allen head plug on the bottom, and the new longer plug it the side. Took all freaking day to change 7 oz. of oil. The F bombs didn't help, but I used a years worth that day!!

Man, that is so funny. My knuckles are killing me today. Yeah, I had a few F bombs last night in the garage. The bottom drain hex bolt came right out. With very little force. Polaris must have the Incredible Hulk working part time for them because that's who put this freaking bolt on. 12 lbs of torque my a$$. Feels more like 100 lbs.

 

I must have been a bit lucky on mine. I did not know they were hard to get out. When I was unable to make it budge with a normal socket I went straight to a 3' breaker bar. Good advice given about making sure the allen is all the way in there! The pop noise was pretty loud....I was happy to see everything was OK. I put some Amsoil in with an ounce of Tufoil! That should do the trick!

 

I had to use a hammer and chisel. Then bought a new plug.

 

I had a devil of a time with my fill plug also. I gave my dealer an earfull and asked them if they prep the vehicles, or if I have the factory to thank. They gave me a substantial discount on the spendy replacement plug after ruining the original.

I almost didn't get mine out. The hex recess was stripping and I had to pound the bit in to make it grab. It took a decent jerk on the flex handle, instead of a slow pull. It is easy to loosen now, when torqued to spec--never had a problem since. I feel like the tapping on the head, combined with a swift pull, was what got it.

Someone at the factory needs a good swift kick--

 

What's a "F-Bomb" ???

 

​

Come on Tim...you were in the military and you didn't know what an "F-Bomb" was. :rofl3::rofl3::rofl3:

 

The grand daddy of all cuss words! LOL

 

The grand daddy of all cuss words! LOL

Oh MY !!!:scared2: :scared2: :scared2:

 

Update- I finally got the fill plug out tonight. It wasn't the locktite freeze fluid. It wasn't the allen socket on the impact driver. It finally came down to using a hammer and a chisel. I destroyed the plug but at least it's off. I really thought I was along with this issue until the past 24 hours seeing the post and reading other threads about this same exact issue.

 

Feel free to abuse your dealer, they know this is something that "happens" regularly. The good news is, if you torque it properly, it will never be a problem again.

Realistically, there's much more in store with the front diff than replacing the small amount of lube it requires. Whenever I drain that lube, I ask myself "why am I draining this beautiful clean lube?" (but that will depend on how much you actually use the spin dependent 4x4 system). The rear end and engine are the ones that need frequent changes.

 

UPDATE- I called my dealer today and told them my experience with the fill plug. Without hesitation, she said she would order me a new fill plug ($30) and ship it to my home.