504 diff plugs tool
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Thread: 504 diff plugs tool

  1. #1
    ccc
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    Default 504 diff plugs tool

    Hi
    Am after the correct shape plug socket to remove both the inspection & drain hole plugs on the 1973 504 differential.
    Its not a square drive.Its almost a 4 leaf clover shape...

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    Not keen on trying to make one.
    Anyone have a spare one or know of a supplier?
    thanks

  2. #2
    1000+ Posts Peter Chisholm's Avatar
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    I've only ever seen square drive fill and drain plugs on 504 diffs. Maybe it's not the original one?

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    Fellow Frogger! TassieExec's Avatar
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    The plugs in question may be square drive plugs that have been butchered through the use of the incorrect tool, as that can create something that looks what was described in the original post

    Regards
    Neil
    2pac, addo and Wildebeest like this.

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    Demannu-facturing! Demannu's Avatar
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    Step 1: Buy new plugs and the correct tool.
    Step 2: Chisel old plugs out.
    Step 3: Profit.
    addo and jo proffi like this.
    Scotty

    Melbourne - Dandenong Ranges

    1956 Peugeot 403 - 'Francois' - resto project

    1969 Peugeot 504 - 'Pascal' - daily driver project

    1970 Peugeot 404 Utility - 'Brutus' - resto project

    1978 Peugeot 604 - as yet unnamed - V6 on straight LPG

    1987 Peugeot 505 - as yet unnamed - project car

    1999 Peugeot 406 Coupé - 'Chloe' - 5 speed manual

    2011 Peugeot 3008 XTE HDi - 'Zoe' - hatchback on steroids

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    1000+ Posts Wildebeest's Avatar
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    Step 1,5
    Strike the face of the plug. This will flatten the copper sealing washer/s making them easier to remove.

  6. #6
    Demannu-facturing! Demannu's Avatar
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    Good thinking 99!
    Scotty

    Melbourne - Dandenong Ranges

    1956 Peugeot 403 - 'Francois' - resto project

    1969 Peugeot 504 - 'Pascal' - daily driver project

    1970 Peugeot 404 Utility - 'Brutus' - resto project

    1978 Peugeot 604 - as yet unnamed - V6 on straight LPG

    1987 Peugeot 505 - as yet unnamed - project car

    1999 Peugeot 406 Coupé - 'Chloe' - 5 speed manual

    2011 Peugeot 3008 XTE HDi - 'Zoe' - hatchback on steroids

    2014 Peugeot RCZ - 'Remy'

    1999 Range Rover 4.6 HSE - 'Grover' - tow car

  7. #7
    Fellow Frogger!
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    Should be an 8mm square I think.

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    1000+ Posts Beano's Avatar
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    Peter Chisholm and TassieExec are correct.

    Just grind down the end of an allen key into a square shape. When you're then using it, you can use a socket on the other end.

    Quote Originally Posted by Wildebeest View Post
    Step 1,5
    Strike the face of the plug. This will flatten the copper sealing washer/s making them easier to remove.
    You'll only have to do this if it's stuck, which is rare. It is in fact the recommended method, but be careful. My local pug repairer did this years ago while I was watching, and cracked the diff housing. There were 2 normal sounding hits, then the third hit gave a dull sound, and we both knew immediately what had happened. Had to fit my secondhand diff.

    Better to use a hammer that is not too heavy.

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    Fellow Frogger! sfrawley's Avatar
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    These tools were on supermarket shelves in France! I should have brought a few back but our bags were full of fridge magnets.
    Stephen
    '03 P406 HDI
    '16 Renault Master

  10. #10
    1000+ Posts Peter Chisholm's Avatar
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    I've never had to resort to hitting the plug. I know others have successfully done it this way but I've always been fearful of cracking the diff housing. Once or twice I've got out a small cold chisel on the edge of the plug and tapped it loose. You end up with a dodgy looking plug though.

    You used to be able to buy square drive sockets off the shelf around the traps and it may pay to check.

  11. #11
    Fellow Frogger! Pug72's Avatar
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    I purchased my 8mm square drive through Snapon tools

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    Fellow Frogger! julian b's Avatar
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    The original plugs would have had square holes .If yours resemble clover leaves someone has probably changed the plugs and sockets should be available to fit from Total Tools or Repco . I have had 504s that have the plugs changed to protruding square drives that are easy to find tools for.

  13. #13
    1000+ Posts Wildebeest's Avatar
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    Geez! What sort of hammers were you using to strike the plug. Club hammers?
    I should have added, Strike the face of the plug using a soft faced, copper head hammer.

  14. #14
    ccc
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    Hi all
    Have just used a home made 8mm sump plug male drive to remove the inspection plug in the diff & top up the diff..
    It was made from an old 18mm zenith galvanised bolt.
    The bolts shaft diameter was 11.9mm.
    The square profile is 7mm long (ended up a 7.7 *7.7mm square) was hand filed into the unthreaded part of the bolt.
    The length of the bolt ended up only 23mm.
    About a 1/2 hour job needing a good vice, file & a vernier guage.
    Curiously the remover wont fit the drain plug (tool large), so will make another.
    cheers

  15. #15
    1000+ Posts Peter Chisholm's Avatar
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    Well done and a cheap solution!

  16. #16
    1000+ Posts Beano's Avatar
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    Quote Originally Posted by Wildebeest View Post
    Geez! What sort of hammers were you using to strike the plug. Club hammers?
    I should have added, Strike the face of the plug using a soft faced, copper head hammer.
    The Pug mechanic in question had meaty forearms and a bit of a temper

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