Diff fill plug threads big problem HELP!!!

[brans72]

ok long story short my fill hole plug on my 12 bolt was not coming out period!! So I driled and drilled and used bits to grind away to finally get it out and I did but now them problem: I used a 1/2 by 14 npt to retap but I am missing little on the left side. I wanna know what tap size I can use now to fix it? I know I will have to go over size/find plug to fit and helicoils are not cheap!!! So can anyone lead me a hand on figuring this fix out?? Brandon

[GetMore]

Maybe just use some silicone when you install the plug?

[kochevy67]

No problem, you can use a plumbing expansion plug. There is no pressure in the differentail so it just needs to be sealed.

[brans72]

Great idea now if I can find one that looks close to a factory look or a cool factor! Thanks and yes I have learned a lesson on plugs Guys!!!!!! Anymore ideas feel free to shot them my way. Brandon

[David Pozzi]

If it's a small area, fill it with JB weld epoxy, then run the tap in again.
How about a 3/4" pipe size? it's about .200" larger.
http://www.korit.com/tapndrill.htm

[brans72]

It is a small area say so wider then a finger nail on the pointer finger (average hand not monsters). 2 ideas I like now. Thanks and keep them coming guys!

[rixtrix1]

Got a pic to post? If so, it may open up some other avenues to explore.

[Top355x]

Weld a plug into rear end cover and epoxy factory hole shut

[D Impala95]

Shouldn't be too hard to drill out to 1" and tap with a 1" npt tap. No Heli-coil will be needed. If you go this route I would suggest draining the differential and cleaning it because of shavings that may have gotten in. The plug you need will be a 1" with a 1/2" internal square drive.