Finally got the plug off but of course ran into another problem--one of my drill bits broke off inside the case. It wasn't in the oil or on the magnet when I just drained the oil, so I guess it's still in there somewhere.

UGGH...

 

get a magnet on a rod and go fishing. Drill bits are hard and won't chew up easily by gears.

 

Get a mechanics magnet.

http://www.google.com/products/catal...ed=0CGgQ8wIwAA

 

Got out the bit. I tried a magnet but it kept sticking to the inside of the case and wouldn't move around! Finally just stick my finger in as far as I could and felt everywhere. It wasn't where I thought it'd be.

Thanks to all for the help. I'll refill it tomorrow....spent about 3 hrs getting that plug off, so I'm spent.

 

So you have another drain plug already?

 

Your plastic plug should also have a large slot on it, use a large flat head screw driver and remove it.
Make sure you order 2 new brass replacements cause the front will fail also at some point.

 

When the first one got rounded, I ordered a new one and let the car sit til the new one came.

 

That was what I tried first--I had a screwdriver that fit the slot perfectly. But when I turned it, it actually chewed up the plastic til it became a circle rather than a slot.

I ended up getting it with a hacksaw (cut across the plug as deep as I could), then inserted the edge of a putty knife and twisted as hard as I could for about 20 minutes. Finally gave way and unscrewed.

Not sure how I got it so tight in the first place.

 

5 years later--went to replace the front diff fluid and of course the plastic plug wouldn't budge no matter how much force i used with a screwdriver and wrench as leverage.

For anyone in the future in the same spot: I was finally able to get it to move using a tire iron (lug nut wrench), which fits over the hexagonal plastic plug head better than anything else I've found.

At least I didnt have to drill this one out. And now, like the rear plug, it has been replaced with a brass plug from rovahfarm....

 

Sorry to bring this one up from the dead... can anyone confirm the part number of the metal/brass fill plug that can replace the rubber ones?
Here's the link to RovahFarm: https://search.cartserver.com/search...+plug&go=GO%21
Looks like #235592 Plug-Drain G/Box S2/3 might be the right part?