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Stripped out torx socket on front differential plugs

This is a discussion on Stripped out torx socket on front differential plugs within the General Member Discussions forums, part of the The RANGER STATION ~ Rangers and RZRs category; Originally Posted by summermn I've been under a 500, 700, 900 last Thursday and today a 1000. All were 8 mm allen Doesnt mean that ...

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Thread: Stripped out torx socket on front differential plugs

  1. #11
    BPS
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    (Robbie) Veteran Member BPS's Avatar
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    Quote Originally Posted by summermn View Post
    I've been under a 500, 700, 900 last Thursday and today a 1000. All were 8 mm allen
    Doesnt mean that maybe a non oem plug got used previously.
    I stand corrected on the Allen size. 6 mm for the engine oil drain plug and 8 mm Allen on differentials and transmission. I have many come in to my shop with stripped holes. A lot of folks doing their own oil changes don't have metric Allen or don't know that the plugs are metric and will use an Imperial Allen. Doesn't work so well.

  2. #12
    1000+ Member Rangerwhit's Avatar
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    Used 5/16 on trans the first time. After allen got stuck in plug, went to an 8. Considering you have a centered hole, the ez out should do the trick. straight or spiral, I'm guessing straight.

    And Steve, you should have been a machinist. You sure have a great detailed library in that head!
    2007 Ranger 500 (Carb)

  3. #13
    (Steve) 1000+ Member pyromedic's Avatar
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    Quote Originally Posted by Rangerwhit View Post
    Used 5/16 on trans the first time. After allen got stuck in plug, went to an 8. Considering you have a centered hole, the ez out should do the trick. straight or spiral, I'm guessing straight.

    And Steve, you should have been a machinist. You sure have a great detailed library in that head!
    Thank you for the compliment. I'm happy about almost every occupation I've ever had but being a firefighter was my forte'. I would not have liked to be a mechanic or a machinist for a living, working at them to survive would have taken the fun out of it. I find both enjoyable becasue I am interested in both and becasue I don't have the stress of depending upon them for a livelihood.
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  5. #14
    (Max) Veteran Member Boomer686's Avatar
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    I have a '15 900 XP both are 8mm, engine is 6mm You will need an extractor, no doubt!

    Food for thought: One thing I learned a long time ago is always check the fill plugs FIRST.
    If you can't get that one off and have already drained your housing / engine / transmission you are 100% pooched!
    summermn, BPS, Rangerwhit and 1 others like this.
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    Veteran Member summermn's Avatar
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    Quote Originally Posted by Boomer686 View Post
    I have a '15 900 XP both are 8mm, engine is 6mm You will need an extractor, no doubt!

    Food for thought: One thing I learned a long time ago is always check the fill plugs FIRST.
    If you can't get that one off and have already drained your housing / engine / transmission you are 100% pooched!
    Same was suggested when I tore into my Xterra. Sure enough the rear diff was badly stuck. Iron plug so stuck it with welder. Used a bit of teflon tape to prevent the issue again
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    Starting Member goatpilz's Avatar
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    Thanks everyone for your comments.

    FYI I have the mechanics manual for the rig and it says it is a torx socket.

    I did the engine oil with the torx and the front diff fill with no problem .

    The drain plug was way to torked in.

    Looks like I will have to drill into the plug short of the magnet as recommended and use an easy out.

    If this does not work I am screwed.

  8. #17
    Veteran Member summermn's Avatar
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    What year is the rig? Post a picture as another suggested please. I may have a couple other suggestions. I've worked on alot of farm equipment and if it wasn't stuck it was probably because it was broke
    Is Polaris getting so cheap they had someone from China do the manual or simple layman not an engineer and the translation got fouled? I've seen similar problems on other things
    Last edited by summermn; 05-21-2019 at 08:14 PM.
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  9. #18
    (Tom) Veteran Member lexiontech's Avatar
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    If your still working on getting it out, try rapping right on the head of the plug with a brass punch and a hammer. Have someone hold your purse if you know what I mean. Or carefully give it a few raps with an air hammer. I don't remember what style of plug it is used on these but I have used this trick countless times on o-ring boss plugs on tractor undercarriages. 3/16 allen head and farmers turn them in until the head strips out. Many times after hitting it with a hammer you don't even need the ratchet you can just spin the socket with your fingers. These plugs may not the ordinary o-ring boss but I figure it's worth a shot.
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    (Steve) 1000+ Member pyromedic's Avatar
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    Many times the judicious application of heat can make a huge difference between difficult, destructive removal and successful removal. The difference in coefficient of expansion between the steel plug and the surrounding aluminum is quite large. Warming the aluminum case will expand the threaded hole more than the steel plug expands resulting in a looser fit and easier removal.
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  11. #20
    1000+ Member Rangerwhit's Avatar
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    Put the impact on her!
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