Front Differential Fluid Problem?

[JohnBN200]

Greetings, I set out today to replace the fluid in the front and rear differentials and the T/C. Started with the Rear and T/C and all went super easy. Pulled off the skid plate to get to the front differential no problem. Started with the fill plug and loosened it and removed it, and fluid started pouring out of the top fill plug hole. Thank goodness I had my catch bucket in place.

I was in total disbelief on how much gear oil was coming out of the hole. I'm guessing at least several ounces. I took quite a while to stop flowing, and when it started dripping I put the plug back in so I can remove the drain plug. Well no luck with that. It was not coming off, even with a breaker bar! After 2 hours of using blaster on it, heat, and everything I could think of, I admitted defeat! I 'm scheduled to take it in to dealer tomorrow to have them take the drain plug out while on a lift.

Any ideas from all of you as to why that gear oil came squirting out of the fill hole? I would think it would be impossible to be able to overfill it with so much gear oil and still get the fill plug in. Looking forward to your thoughts. Thanks!

 

[AThomas0312]

Did you buy this Runner used? The PO could have changed the fluid on a slope in a driveway. Or have you run through water lately? have you checked your diff breathers?

 

[EngRWW33]

I cannot answer the fill amount other than the possibility of a slope when filling (seems unlikely though).

I will say, the only way I was able to get the drain plug (10mm hex) loose in front was using a cold chisel on the edge with a few heavy hits. Only took 3-4 wacks to crack it loose. Obviously, you will have to replace the plug after as it will get gouged in the process, but it works well.

 

[UrbanRunner651]

Was it the transfer case and not the front diff? That would make more sense. Only other guess would be some sort of pressure buildup maybe from a bad seal?
Did you try torching around drain and then holding an ice cube or two on the bolt head until melted? that, with a small breaker bar did the trick for me.

 

[JohnBN200]

I bought the truck brand new. The Toyota dealer did the last differential service on it about 90,000 miles ago. The breathers looked ok to me, but not sure what I’m looking for regarding the breathers.

 

[JohnBN200]

I cannot answer the fill amount other than the possibility of a slope when filling (seems unlikely though).

I will say, the only way I was able to get the drain plug (10mm hex) loose in front was using a cold chisel on the edge with a few heavy hits. Only took 3-4 wacks to crack it loose. Obviously, you will have to replace the plug after as it will get gouged in the process, but it works well.

Thanks for that info. That is exactly what it took. 3 whacks and it broke loose! This forum is awesome!

 

[dropspace]

the plug is something like 18ft/lbs torque based on my manual, so it's common that someone used an impact to get it on there way too tight.

If you torque it to 18 next time you shouldn't have any trouble removing it anymore.

Use new crush washers!