Front dIff drain plug mangled, Need help

[Keith C]

So, I have scraped up my front diff drain plug pretty good while enjoying some trails. Now I have a drip of diff oil from the plug and I can't tighten it with a socket. The square hole has been compromised from the rubbing on rocks so the normal socket won't fit in.
My questions:
1) How can I tighten the drain plug since I can't get a socket in there?
2) What is the part number and where can I get a replacement?
3) Can I remove the drain plug without tearing the plug and threads?

If I can drill out the drain plug I will need to have a replacement for it. I have ARB front diff cover so the need for removing the plug bolt is not really necessary but I want to stop the leak.

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[chevymitchell]

So, I have scraped up my front diff drain plug pretty good while enjoying some trails. Now I have a drip of diff oil from the plug and I can't tighten it with a socket. The square hole has been compromised from the rubbing on rocks so the normal socket won't fit in.
My questions:
1) How can I tighten the drain plug since I can't get a socket in there?
2) What is the part number and where can I get a replacement?
3) Can I remove the drain plug without tearing the plug and threads?

If I can drill out the drain plug I will need to have a replacement for it. I have ARB front diff cover so the need for removing the plug bolt is not really necessary but I want to stop the leak.

You can use a dremel to clean the square up. This is very common.

I’d just weld it shut and forget about having a drain plug.

 

[jhackathorne]

1. Not sure on that one. Only idea would be to maybe Dremel it to get the correct shape back for removal.
2. 68401316AA should be correct @AllMoparParts.com as a source
3. I'd think as long as you can remove the drain plug the threads would be fine. I'd replace the plug though.

And you may want to get a diff skid plate next.

 

[Some Random Guy]

Newer Jeeps don’t even have a front plug. So get it sealed and swap to an aftermarket cover if yours is in rough shape.

 

[Keith C]

Dremel for the win! Picked up a dremel and ground the hole back to squarish again, enough to get a 3\8 socket in there and tighten it up. Thanks @chevymitchell
I do have an aftermarket diff cover (ARB) and I bought a small diff skid but it was after the damage was done.

 

[1996cc]

Now weld it fully closed up.

 

[ChuckQue]

Just throw that ARB on and call it done. Why waste time and effort on the OEM if you already have the better cover?

 

[1996cc]

Just throw that ARB on and call it done. Why waste time and effort on the OEM if you already have the better cover?

The plug and hole we are discussing is in the actual diff housing itself, not in the cover.

 

[ChuckQue]

The plug and hole we are discussing is in the actual diff housing itself, not in the cover.

Ah. I didn’t realize it was in the housing. Yeahhhh, I’d weld that sucker shut.

 

[blnewt]

Ah. I didn’t realize it was in the housing. Yeahhhh, I’d weld that sucker shut.

And get a skid under there

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