Hello. Longtime lurker and first time poster. So I might have performed my all time bonehead move when I was replacing the rear differential fluid. After draining the fluid and replacing the drain plug I put the gear oil bottle next to the fill hole to see if I could squeeze the fluid in or if I needed to use my fluid pump. The next thing I know the damn cap fell in the fill hole. After cursing up a storm for the next half an hour I realized that I have to get that cap out. Any suggestions to get it out? I was thinking of driving the 4runner around to see if the cap can will ground up and perform multiple fluid changes but that thought kind of scares me. But on the other hand I hate to pull the diff in order to get out that dam cap. Any suggestions from anyone how to proceed?
How Screwed am I?
- Thread starter skippy24
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OzarkRunner
New member
Is it just the small cap from the gear oil bottle? If so, I'd think you could remove the drain plug and try to flush it out with the gear oil.
KidVermicious
New member
It's one of those clear soft plastic caps, right? It's way too soft to cause any damage, I'd just drive around and change the oil again in a couple hundred miles.
If you're really worried about it, drain the oil now and if it doesn't fall out, pull the third. It's not that hard.
If you're really worried about it, drain the oil now and if it doesn't fall out, pull the third. It's not that hard.
nevada
Senior Member
yeh, if its just that little cap, just run it. it will be fine.
hell, a trick for refilling diff after doing work on the trail is to have gear oil in a zip-lock bag, and stuff it in the diff before putting the cover on.
driving will grind up the bag, and release the oil. the plastic wont hurt anything.
hell, a trick for refilling diff after doing work on the trail is to have gear oil in a zip-lock bag, and stuff it in the diff before putting the cover on.
driving will grind up the bag, and release the oil. the plastic wont hurt anything.
JohnsD90
New member
It's not ideal, but it really won't hurt anything, there is plenty of stuff people here do that Toyota doesn't approve of.
I was thinking of trying to put an air compressor in the fill hole and trying to blow the cap out the drain. If that doesn't work I guess I'm going to try to remove the third member and get it out. Last night I thought about leaving it in and doing a couple of fluid exchanges using some cheap Supertech 80w-90 after a few hundred miles each (gotta save my Red Line) and convince myself that will be good. We'll see what happens.
I didn't know this trick! Great idea. Filling those diffs is a pain.
Not a petroleum engr, but a plastics engineer. That cap is probably made out of polyethylene. That being the case the melting point is between about 220 and 260 F, depending the PE grade. I don't think the diff oil temp would get that high. However, the heat is going to weaken the plastic and make it even easier to shread.
I agree with the consensus that it should not harm the gears. Gears are made out of hardened alloy steel that's too strong for the plastic cap to have any effect on. My only concern would be if a piece from the cap wedges somewhere, but unlikely. The oil and movement should keep that from happening.
Try inserting one of those pipe cameras that they sell in Home Depot, or one of those scopes used to inspect guns if you have access to any. Maybe you are lucky enough to see where the cap is and figure out a way to grab it.
I agree with the consensus that it should not harm the gears. Gears are made out of hardened alloy steel that's too strong for the plastic cap to have any effect on. My only concern would be if a piece from the cap wedges somewhere, but unlikely. The oil and movement should keep that from happening.
Try inserting one of those pipe cameras that they sell in Home Depot, or one of those scopes used to inspect guns if you have access to any. Maybe you are lucky enough to see where the cap is and figure out a way to grab it.
KidVermicious
New member
Sweet. I think you'll be good to go.
