Hot!'06 Foreman 4x4 stripped differential cap

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camoman33935
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2017/03/12 13:48:13 (permalink)

'06 Foreman 4x4 stripped differential cap

Long story short I have let my 2006 Honda Foreman 4x4 sit for about a year without maintenance. Stupid on my part yes I know but work keeps me really busy.

I am in the process of changing all of the fluids (motor and front and rear differentials). While attempting to remove the full cap on the front differential with the appropriate sized socket, the aluminum head of the fill cap began to strip. So now I am in limbo as to what I can do to get this thing off. It feels as if ithe threads are seized.

Any suggestions on how to unseize and remove the fill cap?
#1

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    toodeep
    Outlaw
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    2017/03/12 16:55:52 (permalink)
    Tap on it a couple times with a hammer and use a good 6 point socket on it.

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    #2
    camoman33935
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    Re: 2017/03/12 22:11:58 (permalink)
    I'll try this again. The only issue is that when it started to strip the socket for that mm now spins freely on it. I may have to file down to get a smaller mm socket to fit.

    Would heat help at all?

    2006 Honda Foreman 4X4
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    #3
    toodeep
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    2017/03/12 22:33:55 (permalink)
    I've removed a lot of them with rounded heads using a good 6 point 17mm impact socket. If it's too rounded you might get an standard socket tapped on enough to work. Heating it will just make it expand so probably won't help.

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    #4
    00_NUTT
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    Re: 2017/03/13 06:57:03 (permalink)
    Just get you a good chisel and catch the edge of the cap and start tapping. It will come right off. Wouldn't be the first time I had to do that. Or get a big pair of channel locks. Just think about it and I'm sure you will get it off.

    00_NUTT
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    #5
    Jeepwm69
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    Re: 2017/03/13 10:23:13 (permalink)
    Tap on it with a hammer to break the threads loose, then put some vice grips on it to get it off.
    #6
    Welder304
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    Re: 2017/03/18 07:38:13 (permalink)
    Those caps break all the the time and tapping aluminum with hammer will just get to break sooner time to order new caps
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    00_NUTT
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    Re: 2017/03/18 09:18:03 (permalink)
    He already broke it so a new cap was already in his future!!!

    00_NUTT
    1997 Honda 300 4x4
    Head Ported and Polished
    317 Kit
    Big Red Cam
    Clutch Kit
    SuperTrapp IDS2 Exhaust
    K&N Filter
    Carb Kit
    32" Interco Interforce II's
    16" MSA M30 Trottles
    Snorkled 
    54% gear reduction
    Honda 350 rear axle assm.

    6" BPC CUSTOM LIFT WITH 8" STRETCH AND 3" BODY LIFT OLD 300 LOOKING GOOD AS EVER THANKS TO WHITNEY!!!!!

    SON'S BIKE
    1998 Honda 300 2x4
    6" BPC LIft with some sick a-arms
    420 spindles and disk brakes
    29.5" OL2'S
    14" MSA M26 Vibes
     
    Upcoming
    4x4 Frame and Motor that's here now just got to get to work on the swap over!!!
    54% Gear Reduction
     
    #8
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