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[MarkG]

After 11 years, 200k miles and a slight leak which 'sealed itself' some years ago (hope that doesn't mean it's empty), I decided it was time to change the diff oil. So I bought the oil and instant gasket and following MarkDTM's excellent notes, set about the job. Before taking the rear cover off I thought I'd better check the filler plug could be removed. Good job I did because it is stuck fast. After a good wire brushing I can see the internal T50 is completely rounded off. I tried sawing a grove in one side of the plug using a dremmel so I could whack it with a hammer on a screwdriver but it won't shift. Any suggestions for removing it?

[Jimbob]

sure it was t50?  some are allen key fitting, 8mm?

[Jimbob]

yes, this guide details the allen key type

http://www.omegaowners.com/forum/YaBB.pl?num=1157722402

this one shows the torx type

http://www.omegaowners.com/forum/YaBB.pl?num=1161520937

ill edit them both for clarity 

[MarkG]

Whichever size is was doesn't matter much any more because it was already completely rounded off. A new plug is on order from Vaux (only £1.50!) but I'm still left with the challenge of getting the old one out

[Lazydocker]

Whichever size is was doesn't matter much any more because it was already completely rounded off. A new plug is on order from Vaux (only £1.50!) but I'm still left with the challenge of getting the old one out

If it's that tight, perhaps cover off and get it on the bench to give you a better chance? :-/

Perhaps you can get the plug in a vise and turn the cover after copious amounts of Plus Gas?

[Jimbob]

mine was more sort of recessed iirc, so not sure that would help.

prob grind a groove in and screwdriver / chisel off?

mine wasnt tight  / seized at all, so hopefully wont take too much to undo

[MarkG]

Filler plug is on the drivers side of the diff casing, not on the backplate so getting it out needs to be done in-situ

[Lazydocker]

Filler plug is on the drivers side of the diff casing, not on the backplate so getting it out needs to be done in-situ

Yep... Moment of blondeness on my part

Just perseverance I suppose... Like Jimbob says, perhaps a groove might help or some gentle heat :-/ :-/

[Omegatoy]

dont mess about, just weld a nut to the filler plug allow to cool and undo, the heat will crack the seal that has occured aiding removal, make sure the nut is big enough so you can weld through the hole in the nut into the inside of the filler plug hole where the torx/allen key has rounded off !!

[robson]

I have wondered in the past what needs disconnecting on the car  if using a mig welder

[Omegatoy]

Personally i have never disconnected anything on any of the hundreds of cars i have welded up including Omega,s
 with modern cars i simply make sure the key is out of the ignition,
never had a problem, however i see many warnings about always disconnecting the battery, but to my way of thinking as long as the earth clamp and the torch are close together then the current only flows between the two, it certainly does not go whizzing round the whole car!! only time i have disconnected the battery is when i welded a hole beneath the battery tray and a new battery tray in, others may disagree but im simply stating what works for me!!

[Marks DTM Calib]

Disconnect the battery and short the pos and neg leads together.

That way there is no risk of instant damage or shortening the life of the IC;s by damaging the parasitic diodes in them.