Differential Fluid Change Fiasco

[CC4R]

So I decided that I would finally change the differential and transfer case fluids today after having the supplies for over a month. All went well until I got to the front diff. I removed the skid plates and popped off the fill plug. When I went to undo the drain plug I couldn't quite get the 10mm hex bit socket all the way straight in. After fooling with it for a good 15 minutes I decided to get a BFH. Big mistake, in the process I stripped the hex on the plug. Is there any way of changing the hex bit plugs to standard plugs?

 

[4RunnerFan]

I ended up using a Dremel tool to grind down the center area of the hex bit I bought for the job so that the outside corners of the bit had more bite (if that makes sense). Once I got the plug out, I made sure to replace it using some Anti-Seize on the inside flange of the plug where it contacts the diff, and to use a micro torque wrench to tighten it to spec. What a huge difference the next time I had to do the job. Piece of cake.

Maybe you could try the grinding bit trick, but you might want to invest in a new replacement plug before you remove the old one.

 

[zopperman]

grade 8 nut welded to the plug. bought a new plug to replace it but decided this one was easier. Impact fits right in there

 

[CC4R]

I'm gonna try fixing it tomorrow since I'm working all day today. I managed to get a new plug from the dealer. Village Toyota Parts if anyone is interested for that matter.

 

[zopperman]

You could also try a BFH and chisel to the side of it.