2nd Gen Non-Engine/Transmission Mag-Hytec Dip Stick Over tightened

[ph]

Hi Guys, Happy Thanksgiving.

I just picked my truck up last night from having the differential rebuilt. New carrier bearings, axle bearings, and seals. I gave a copy of the Mag-Hytec installation instructions to the service writer and pointed out the 30 in. lbs. part asking that the tech please follow them. In retrospect that may have been not too smart on my part. The drain plug and reference plug are fine. The dip stick is so tight that tapping hard on the allen wrench with a hammer does not move it. Any suggestions for removal without doing more damage would be appreciated. I'm hoping that he snugged it up in a warm shop and the cold outside contracted the aluminum. Is that wishful thinking? TIA, ph​

 

[GReed]

Mine was tight one time and I eventually got it by using an open end wrench over the allen wrench for leverage. It may not have been as tight as yours. Maybe they used ft lbs instead of in lbs. You might try putting a bit of dry ice around the dipstick and then heating the outer area with a heat gun or hairdryer. One of those spray air cans for cleaning computers & such turned upside down may get the dipstick cold enough to shrink it a bit.

 

[TRAMPLINEMAN]

Hi Guys, Happy Thanksgiving.

I just picked my truck up last night from having the differential rebuilt. New carrier bearings, axle bearings, and seals. I gave a copy of the Mag-Hytec installation instructions to the service writer and pointed out the 30 in. lbs. part asking that the tech please follow them. In retrospect that may have been not too smart on my part. The drain plug and reference plug are fine. The dip stick is so tight that tapping hard on the allen wrench with a hammer does not move it. Any suggestions for removal without doing more damage would be appreciated. I'm hoping that he snugged it up in a warm shop and the cold outside contracted the aluminum. Is that wishful thinking? TIA, ph​

Get yourself a set of the hex bit sockets for a ratchet. This way, you're using the leverage of the ratchet handle and it'll come out a lot easier.

 

[Cummins12V98]

Slip a socket over the stud the allen wrench goes into and tap the top of the socket then do as suggested using an allen socket to try and remove. The tapping usually works.

 

[ph]

Thanks to all for the suggestions. While obsessing this afternoon in a turkey induced trance, I'm now wondering if it has been cross threaded. There was some fluid on the side of the cover coming from the dipstick area. At the time I noticed the fluid I thought it was from the recent filling after the repairs. Would, could this have leaked during the ten mile long, maximum 45mph drive home from the shop? Not sweet dreams tonight. ph

 

[GReed]

The threads are pretty course. The rubber O ring is probably messed up. Hopefully, anyway, the O ring would be an easier fix.

 

[ph]

The threads are pretty course. The rubber O ring is probably messed up. Hopefully, anyway, the O ring would be an easier fix.

Absolutely. I've got my fingers crossed.

Now, hoping the o ring is just crushed but how much of a problem will o ring debris or aluminum pieces be in the differential? Drain and refresh?
ph

 

[Ozymandias]

That doesn't hurt the internals in any way, aluminum and rubber are far softer then all the hardened steel surface in Bearings and Gears.

No need to think a second about it.

 

[ph]

That doesn't hurt the internals in any way, aluminum and rubber are far softer then all the hardened steel surface in Bearings and Gears.

No need to think a second about it.

Thanks ozymandias. That's a relief.

 

[ph]

Well, after studying each and every suggestion you all gave I used all of them. This morning armed with a 10" long 3/8 break over bar for leverage, a socketed hex bit, a 5/8 deep socket with a hammer to tap it with, the upside down computer duster to cool the stem base (the cover was warm from a 30 minute drive), and more force than I felt comfortable using on aluminum, the stem is free with the threads intact. The o ring is definitely shot.
My thanks goes out to each and every one of you who took the time to help an old man.
ph

 

[TRAMPLINEMAN]

Glad to hear you got it apart and it's just the O ring. Also, glad to help. I've been helped by many on here and it's saved me thousands.

 

[Ozymandias]

That's why we are here.

 

[ph]

T-he TDR members and TDR supporting venders are the greatest. I called MAG-HYTEC to order an o-ring for the dipstick and today in the mail I received an entire o-ring set at no charge. That's great customer service from a great vender.
Thanks Mag-Hytec
ph

 

[seafish]

Not sure if anyone has suggested it yet, but since aluminum threads DO tend to gall, it's a good idea to use some antisieze on both the dipstick and drain plug threads.

 

[Dieselgunner]

The next time that you have any of the plugs so tight, take a center punch and set it on the dipstick, drain plug, or reference plug toward the outer edge of it and tap the center punch sharply driving the plug counter clock wise to loosen it. I have done this many times on many different plugs and such and it has worked each time. It will leave a small dimple on the plug, but guess what? You can use it over and over if your tech is a gorilla.