Lose fill plug

breda65 · #1 (**permalink**) 04-23-2008, 07:55 AM

I was checking my Diff. oil level and noticed that the threads on the diff side of the plug are worn. the plug is lose. I took some pipe tape and made the joint tight and it seams to be holding. Is there a way to fix this problem?

**Andrew** · #2 (**permalink**) 04-23-2008, 08:47 AM

So the threads in the diff housing itself are messed up? Short of welding (JB welding?) and re-tapping, I'm not sure what you can do. Teflon tape sounds like a good idea, or how about some plumber's putty?

If the fill plug itself is the culprit, replacing it would obviously help.

Andrew

breda65 · #3 (**permalink**) 04-23-2008, 08:57 AM

the plug is fine. Looking at the threads they have not been cross threaded they are just wearing out. I'm not sure that JB weld would work because of the oil. I don't like using the tape because I can't really tighten the plug.

**Andrew** · #4 (**permalink**) 04-23-2008, 09:16 AM

That's the problem with a brass plug and aluminum housing; they're both soft. The plug does not need to be super-tight, but it sounds like someone has over done it in the past.

Short of welding and redrilling, or heli-coiling, I don't know what to say. I don't think either is an option without disassembly, which I doubt you want to get into. It's a very shallow thread, and the ring gear is right there, millimeters away inside.

I'd go with plumber's putty after cleaning the threads as best as you can. If the leak is not bad, I would just monitor it.

Andrew

breda65 · #5 (**permalink**) 04-23-2008, 09:22 AM

I think my plug is steel Because it's silver. Or it is plated brass I've always set the plug using a tork wrench. So I'm not sure how it's happened.

**backfeeder** · #6 (**permalink**) 04-23-2008, 11:39 AM

That was my major problem when I first got my spider. Had to tap the hole and installed a slightly larger plug. The new plug I believe is a 25mm 1.5 thread. Got a metric tap and die set from harbor freight for about $60 and then purchased the plugs from a VW performance web site. Patience and a steady hand should see you through it. Don't forget to use some lubricant. Lubricant purchased at Sears and new washer obtained from VW dealership.

Elio Comello · #7 (**permalink**) 04-23-2008, 02:04 PM

The original plug was BRASS, and metric of course.

TTFN Elio