Rear Axle - Fill Plug Hard to Remove

89ford05

Article No. 89-7-9

AXLE - REAR - 7.5 AND 8.8 INCH - FILL PLUG HARD TO REMOVE

FORD: 1989 THUNDERBIRD

LINCOLN-MERCURY: 1989 COUGAR


ISSUE: A rear axle fill plug that is hard to remove may be caused by the type of plating used on the steel fill plug. The steel fill plug has a negative reaction to the aluminum rear axle cover.

ACTION: Use the following procedure if the rear axle fill plug is difficult to remove.

1. Using a heat gun, apply heat for about 60 seconds to the aluminum that surrounds the fill plug. The heat range should be 500~ to 750~ F.

CAUTION: DO NOT USE AN OPEN FLAME TO HEAT THE REAR AXLE FILL PLUG.

2. Immediately remove the fill plug by using a 3/8" flex handle.

3. When the fill plug is reinstalled, tighten it to a torque of 23-25 ft.lbs. (34-47 N-m).

NOTE: LUBRICANT LEVELS IN FORD DESIGN REAR AXLES ARE NOT TO BE CHECKED AT PRE-DELIVERY OR ANY OTHER TIME DURING THE LIFE OF THE AXLE UNLESS A LEAK IS SUSPECTED OR REPAIR IS REQUIRED. ALL FORD DESIGN REAR AXLES ARE LUBRICATED FOR LIFE AT THE FACTORY.

OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 5960, 5970