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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; My rookie advice is slow down...post some pics....you said socket stripped so I assume it's the plug that stripped and not the wrench. There is ...

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Thread: Stripped out torx socket on front differential plugs

  1. #21
    Veteran Member TX 3400XL's Avatar
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    My rookie advice is slow down...post some pics....you said socket stripped so I assume it's the plug that stripped and not the wrench.

    There is a vent line you may be able to insert a suction tube in to pump out fluid with a vacuum pump....then remove the overfill plug to make sure you insert correct level fluid.

    Short of that I would explore tapping an over sized Allen or torx whatever fits into plug and give it a try....

    Pics will help ALL cypher best attack
    Rangerwhit likes this.

  2. #22
    (Richard) Elite Member Mossy700's Avatar
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    Since this plug is not totally recessed into the gear case, it could probably be turned using a dull cold chisel or flat nosed punch and a hammer. I have removed many stuck bolts and such over the years like this. You just have to be careful and not damage the gear case housing. I also looked at those torx extractors and if you are sure the plugs are torx, they might work. All the plugs on both my machines are allen. I have an old handheld hammer impact that has removed many stuck bolts and screws, but I'm not sure how strong the gear case housing is. Every time I try to use an EZ out on something really stuck tight it breaks.
    I also put never-sieze on those plugs.
    Last edited by Mossy700; 05-22-2019 at 07:02 AM.
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  3. #23
    (Larry) 1000+ Member pede58's Avatar
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    Those dam things like to get tighter and in kind of a bad spot. Your best bet is to take as big of a hex nut as you can get in there, inside should not be larger then the plug, hold it on and mig weld the inside to the plug, then use an impact.

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  5. #24
    (Kris) 1000+ Member jungleman's Avatar
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    Quote Originally Posted by summermn View Post
    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
    Just because it says it in a PO service manual, doesn't mean it is so.....Sorry to say, many times this has been the case..
    Rangerwhit likes this.
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  6. #25
    (David) Starting Member PlayBoy51's Avatar
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    Rangerwhit said; Put the impact on her!
    I just fixed a 2016 900 Ranger that had been stripped
    He brought me the buggy & a new drain plug & said he stripped it with a torx bit
    The new plug is OEM Polaris 8mm Allen (Hex)
    I just got a bigger torx, tapped it in with a hammer & impact zipped it right out
    jungleman likes this.

  7. #26
    1000+ Member Rangerwhit's Avatar
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    Quote Originally Posted by jungleman View Post
    Just because it says it in a PO service manual, doesn't mean it is so.....Sorry to say, many times this has been the case..
    There is one in mine where it says ft lbs and should be in lbs. Owner beware! I like the bigger torx and impact idea. Where are the pics?
    2007 Ranger 500 (Carb)

  8. #27
    Veteran Member summermn's Avatar
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    Quote Originally Posted by PlayBoy51 View Post
    Rangerwhit said; Put the impact on her!
    I just fixed a 2016 900 Ranger that had been stripped
    He brought me the buggy & a new drain plug & said he stripped it with a torx bit
    The new plug is OEM Polaris 8mm Allen (Hex)
    I just got a bigger torx, tapped it in with a hammer & impact zipped it right out
    Is there a rash of this happening because people are doing as the manual suggests and using the torx? Looks like shops are getting a nice gimme

  9. #28
    BPS
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    (Robbie) Regular Member BPS's Avatar
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    Quote Originally Posted by jungleman View Post
    Just because it says it in a PO service manual, doesn't mean it is so.....Sorry to say, many times this has been the case..
    I looked in the service manual for the 900 xp and it doesn't mention what tool to use. I believe the OP might be confusing torque with torx.

  10. #29
    (J.D.) Regular Member NotAnEngineer's Avatar
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    Quote Originally Posted by summermn View Post
    Is there a rash of this happening because people are doing as the manual suggests and using the torx? Looks like shops are getting a nice gimme
    It seem like a rash of common sense not being so common anymore. I've had to replace my front diff plug because the allen wrench STARTED to get some slack when it was inserted. Gotta be proactive!
    jungleman likes this.
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  11. #30
    Veteran Member summermn's Avatar
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    I just went to the maintenance section and what I see is "fill plug torque" and "drain plug torque". No mention of the wrench needed.
    BPS and yooper265 like this.

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