PBB + Hammer
Well I attempted mine this weekend. The t-case was simple. The differentials were impossible.
Rear diff fill plug would NOT come out. Tried a huge 1/2" drive ratchet with 24mm socket, no dice. Tried a 15/16 6-point socket, no dice. Tried a box end wrench, no dice. Tried a chisel and hammer, no dice. So, didn't even attempt the drain plug. I will order new plugs from the dealer and when I get them I'll have to cut the existing plugs out somehow.
Front diff drain plug would not budge. There are markings on it from where somebody in the past used a chisel and hammer on it to attempt to break it free. I'm not sure if they had any luck or not. But the area around the drain plug is leaking slowly and I was able to get the fill plug out enough to top off the differential fluid.
What a P I T A. I guess the diffs are one of Toyota's weak points. Never seen anything like this in my life. :bash:
I know this post is from March.
Re stuck bolts/plugs. I use the PB Blaster + Hammer method. Spray PBB, whack head of bolt/plug with a hammer 5-10 times. Don't beat on it, whack it. You need not hit it hard enough to deform the head. Spray, Whack, let soak for a few minutes. Spray, Whack, let soak for a few minutes, etc.
The Whack jolts the bolt just a tiny tiny bit, but this allows the PBB to start penetrating the threads. Maybe you need to spray/whack let soak for 15 minutes, lather rinse repeat. Maybe do this 3 or 4 times then then try again the next day. Once the PBB breaches the threads that first little bit, it can make its way deeper down the threads. Patience and follow through.
Regarding the front diff hex head plugs: the hex hole can get packed with grime and oil. The hole is partially filled with this crap and the hex wrench cannot seat in all the way. Spray PBB blaster, WD 40, anything in the hole and scrape out the muck. Get that hole clean bc that hex wrench/socket needs to be fully and squarely inserted.
I used a brand new hex wrench with a small pipe as an extension for extra leverage.
Using a torque wrench when reinstalling drain bolts makes them tight enough to hold without making them so tight you cannot undo them.