As I try to remove the fill bolt on the differential the bolt on there is too tight and now my bolt headed are starting to round off and the 23mm wrench aren't having any grip on it anymore. Any idea on how I can get this to remove I have the new bolt to replace it once the old come out after the fluid change? Checking Sears to see if they have a Craftsman Bolt out kit but the max size only goes up to 19mm .

 

vice grips?

 

man thats a friggen tight area even with the proper socket working. Hmm, can you somehow cut a notch in the plug and use a long chisel to get it loose?

 

Are you using a 12 point socket or 6 point? Try the 12 if its stripping, maybe a 22mm could be hammered on to the plug or I second notching it with a dremel tool and using a chisel.

 

Are you brave enough to give this method a try:
http://youtu.be/EqNcBkLvptg

 

I'm having a hell of a time getting my fill bolt off, I gave up when I saw the bolt starting to round off. Any suggestions?

 

hammer on a smaller size and replace with a new bolt.

 

This. Then tap with hammer.

 

A little advice, don't pull or push on the wrench when you're trying to loosen the bolt, instead give it a smack with the palm of your hand, the sudden shock usually loosens the bolt and you don't run the risk of rounding it.

This works with all bolts.


As for the OP and others with already rounded bolts, try vice-grips as mentioned above or hammer/chisel.

 

If the bolt isn't completely lost, then this is the advice to go with. This is exactly how I get my diff bolt open when it's acting up. Use physics to help you: smack the wrench towards the end of the handle (or use a longer wrench) to get more torque.