Anyone not get the front differential drain plug out?

[Gatafly]

Wahooo!! I got it loose!!​

I was under the 4runner this after noon bringing the tranny fluid up to the proper temp so I could check the fluid level again. I had just changed all the fluid last week and wanted to run it a bit before final level check. While under there I was staring at that frozen differential drain plug and decided to try what the local Toyota 4wd specialist tech said they have to do. I gave it 4-6 whacks with a ball peen hammer and then took a chisel and placed it on the edge of the drain plug and gave it 2 good whacks and bingo, the plug twisted loose. I am now good to go. Thanks for some words of wisdom and a little push to go beyond what felt right.

:banana::banana:

 

[Jeff T]

Go ahead, admit it. The spinach worked!

I sense the relief! Congrats!!

 

[message]

I was anticipating a fight when removing the front diff plugs however both came out relatively easily without any damage. I made sure to torque them to spec with new crush washers, so I assume they will come out just as easy next time.
Also note I had 126k on the 4runner and I know the front diff fluid had never been changed.

 

[004Gunner]

While under there I was staring at that frozen differential drain plug and decided to try what the local Toyota 4wd specialist tech said they have to do. I gave it 4-6 whacks with a ball peen hammer and then took a chisel and placed it on the edge of the drain plug and gave it 2 good whacks and bingo, the plug twisted loose. I am now good to go. Thanks for some words of wisdom and a little push to go beyond what felt right.

Thanks for posting this tip! I just used a chisel to get my front diff fill plug loose and it worked great! I could have reused the plug too but I had already bought new drain and fill plugs. Now I'm just hoping the Mobil 1 synthetic won't flow out the breather like the Amsoil did.

 

[Benski]

All went well changing tranny, transfer and differential fluids until that last bolt!

Damn that front differential drain bolt! It tried lubricant, banging on it, extra leverage and finally an impact wrench-stripped! Pumped out what I could from the fill bolt and refilled it. I came in and looked here to find that many of you have had a similar problem. Next I'll try the chisel.

 

[lelandr]

After quite some impacting, hammering, chiseling with no luck, I had a mostly stripped out bolt. I took a chance and used a jack with a breaker bar. It was a bad day for the drain plug, but it's out.

Hope this helps someone.

 

[btownie]

I had a half stripped, frozen drain plug this past weekend. (the fluid dripping off is WD40 not diff fluid)

I soaked the plug in WD40 for about an hour. Used a stubby 10mm impact hex and tapped it into the plug.

1 and 2 on the ol' Milwaukee didn't budge the plug so I gave it "the beans" level 3 power :lasercannon:
and it broke loose. I did not have a catch pan ready and when it zipped the plug straight out I dumped black stinky gross 100 year old gear oil all over me. But I got it!

I did attempt to use a breaker bar first but could feel it starting to round off the plug.
I also used a pick to clean out the allen hole in the socket beforehand.

I did pump a bit of clean oil through the diff before I filled it back up.
Also new plug is on order...

 

[Bumbo]

I tried it and lost... buggered it up pretty good. Ended up having the dealer air hammer the drain plug off an finished the job. Rear was fine, front PITA.

Rear was fine. I wish the would use bolts like they do back there. Much easier to remove.

 

[UrbanRunner651]

next time just try lightly torching around the housing and then melt 2-3 ice cubes directly on the bolt head before hitting it with a breaker or impact.

 

[lj4r]

My front differential drain plug seemed to be frozen solid. I soaked it in pb blaster for a couple hours, no luck. I tried a craftsman 10mm socket on a breaker bar, it snapped the Allen part off of the socket.

I soaked it again, heated it up with a propane torch and then put ice on the drain plug. Used a new 10mm 1/2 inch drive with a 16 inch ratchet, it came right off. (I had Freeze Off on order, it is supposed to be great).

Drained the fluid and went to put on the New crush washer, discovered that the dealer sold me four of the same washers. (Now I am wondering if I put the wrong washer on one of the rear plugs............

The front drain plug is different, From the fill plug. Back to the dealer in the morning.

Thanks for the suggestions.

Phil

 

[mastee]

I will second grinding the hex socket flat i.e. take the beveled edges off to prevent rounding the plug, I read it on a few other forums as well.