Front Diff drain plug is stripped, how to remove?

I went to change the front diff fluid today and the fill plug was tight but it came out ok. When I went to remove the drain plug I ended up stripping it. I was using a 10mm hex socket and a breaker bar plus pushing on it with my feet and it would not budge. Someone at the factory or dealer was happy with a impact gun or a big wrench. The hex socket still fits but it is pretty much stripped.

I gave up getting the drain plug out so I put the bottle pump hose down into the fill hole and pumped out about a quart of fluid. I stopped pumping out after a quart because the fluid looked clean a and new. I them pumped in a quart of new fluid until it ran out of the hole and called it good. My truck has currently has 57k miles on it.

I dont use 4x4 a lot at all so I guess I wont worry about it for quite a few more miles but at some point it will need addressed. So, any ideas or tips on how to get the drain plug out? Could it be chiseled loose, drilled through the center and tapped or something else?

 

Consult "the chart."

 

This thread might really help you out, good luck.

https://www.tundratalk.net/threads/replacement-front-diff-drain-plug.127106/

 

Yup, I found that too after posting thank you. I guess this is a common problem and chisels, heat and determination are whats needed.

 

I took mine to a local shop and asked them to weld a nut to mine, then break it loose while it was still hot. Before doing that I bought a new one from the Toyota dealership. Welding the nut on is the ultimate weapon, so why waste time screwing around and getting frustrated?

 

A quality cold chisel makes quick work of it. Or welding a sacrificial socket on it even quicker.

 

Also hitting the head of the bolt with a hammer or brass drift helps shock the threads loose while compressing the washer, hopefully enough to get it loose

 

I just noticed it's not fully stripped yet. I would do as suggested above and try tapping it in with a hammer. Or get a sacrificial torx bit that's a hair larger and hammer that sucker in so it bites into the nut. Or the other suggestions above.

 

Once you get it out replace it with this. A notorious problem. Credit to someone on this site for teaching me this.

 

Insert a hex bit, smack it with a 5lbs hammer like you to drive it through once. Then remove it.This type of thread always acts like this on the 1st removal.

 

yeah i learned always go after the drain plug first

 

you will get it though, in easy area at least

 

It’s always good practice to loosen the fill plug first. What if he drained the diff and then couldn’t get the fill plug free? Would be a bad day.

 

oh shit your right I said it backwards. so yeah nothing done wrong. couple beers tonight

 

Yes I made sure the fill plug came out first.

 

I welded mine, this was a couple years ago. Worked awesome.

 

Air hammer with a chisel bit. Couple taps and it turned for me.

 

This is the easiest, most reliable, and least frustrating solution.

Your problem also highlights why you always remove the drain plug last.

 

So that's where my 10mm is....

 

Humm, I wonder if a big glob of JB Weld on the hex socket and plug would hold enough to crack it loose? Also if I use a chisel should I use a flat cold chisel or a punch type?

I have the fluid replaced and it doesn't need maint. again for quite a while but now it is just irritating and a challenge to get it loose.

 

Also the plug looks like aluminum, can it be welded with a normal stick welder or do I need a special setup?

 

I did the same thing on my Tacoma. The heat from welding definitely helped.

 

Get yourself the one on the right next time. Not all 1/2" drives are the same lol. A little PB blaster and some leverage works wonders.

 

I am extremely doubtful the plug is aluminum... similarly doubtful that JB Weld would give the bind needed to break it free.