2005 Pathfinder: Another stripped diff housing

[racerken]

Hi, this post number 2.

I stripped or I believe I stripped the housing threads to the diff housing drain plug. The housing is aluminum and the drain plug is cast steel.

This is what happened:I used a 1/2" breaker bar to remove the plug since it was glued in. Then when I tightened the plug I used the same breaker bar.... well after 1 snug torque, it went alittle easy on me. I immediately stopped. this was about 6 months ago so I'm sure it won't fall out. BTW, the proper torque is something like 35 foot-pounds.

This is making me lose sleep so one day I'm going to have to replace the rear diff cover. Has anyone done this? It appears that the read diff is mounted to a cross member so I would think that I can get away with remove the main drive shaft only and not the left and right? would this get me enough room to slide the diff forward enough to allow for the diff cover to clear the gears inside? or, do i have to remove all drive shafts and hold this diff housing on a jack?

My options may also include removing the plug on my next oil change and drill/tap but then I'm afraid that some metal may get inside...

Any assistance would be great.

BTW, I;m into changing fluids because my past pathfinder, a 96 ran into some serious problems because for one, I drove it like a wild man and two, I did not change transmission or diff fluids until about 50k. I discovered particles in the transmission and rear diff and both started making noise at about 130k. Again, i beat the junk out of it by hitting every tree my bull bar would take-on. I once hit a deer and won.

[Empty V]

BTW, I;m into changing fluids because my past pathfinder, a 96 ran into some serious problems because for one, I drove it like a wild man and two, I did not change transmission or diff fluids until about 50k. I discovered particles in the transmission and rear diff and both started making noise at about 130k. Again, i beat the junk out of it by hitting every tree my bull bar would take-on. I once hit a deer and won.

Welcome to the forum! BTW I've got 200K miles on my 01 QX4 and I'm just now changing the rear diff oil for the 1st time. I guess I'm not the best person to be giving out advice.

Billy

[racerken]

Thanks for the welcome.Yeah, I read your story!

did you pull your plug out? I think the best idea was to get a short 1/2 extension and weld it into the stripped plug. Then you have a fresh 1/2" square plug again.

[Empty V]

Thanks for the welcome.Yeah, I read your story!

did you pull your plug out? I think the best idea was to get a short 1/2 extension and weld it into the stripped plug. Then you have a fresh 1/2" square plug again.

No I'm going if on Friday to finish my exhaust and I'll ask the dude to do weld the extension in for me. I'll probably have pics of the stripped plug tomorrow.

Billy