My Front Diff Hex Bolt is all Chewed up! - TTORA Forum
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post #1 of 31 (permalink) Old 05-24-2006, 10:58 AM Thread Starter
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Unhappy My Front Diff Hex Bolt is all Chewed up!

In my multiple attempts to remove the front 10mm Hex bolt drain plug from the front diff on my 2000 Taco 4x4 I have stripped the bolt up.

I am almost certain that the fluid has never been changed given the condition of the rear and transfer case fluid when I changed them. When it came time to remove the front drain plug I could not get it to come off. Using my huge breaker bar and lots of liquid wrench the drain plug refused to break loose. And after applying enough force I eventually stripped the nut up.

My question is how should I go about removing the drain plug now that itís stripped up? If it was a regular socket bolt I could use a "bolt out" style bolt remover except this is a hex nut style bolt. Do they make removal tools to use in these style nuts?

Thanks
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post #2 of 31 (permalink) Old 05-24-2006, 11:00 AM
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post #3 of 31 (permalink) Old 05-24-2006, 11:13 AM Thread Starter
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I wish it was that simple.

anyone?
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post #4 of 31 (permalink) Old 05-24-2006, 11:36 AM
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Weld a old lug nut or something you can get a socket on to the plug. I have a diff sittting on my bench right now with that same problem and am going to get a buddy to weld something to it so I can remove the plug with a socket.

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post #5 of 31 (permalink) Old 05-24-2006, 11:42 AM
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If worse comes to worse, you can pull the diff out and empty it through the CV sockets.

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post #6 of 31 (permalink) Old 05-24-2006, 11:48 AM
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They they make a hex type of remover for stiped bolts. Im not sure who i knw snap-on makes them.

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post #7 of 31 (permalink) Old 05-24-2006, 11:59 AM
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I hammered a torx socket into mine worked awsome, i cant remember the size, use a size slightly bigger than the hole. but it beats welding to it.

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post #8 of 31 (permalink) Old 05-24-2006, 12:03 PM
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You can use a reverse twist extractor bit.

Please wheel responsibly.

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post #9 of 31 (permalink) Old 05-24-2006, 12:04 PM
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That sucks. I bruised my hand last time I removed my front diff plug. A real bitch. Try the weld method detailed above.

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post #10 of 31 (permalink) Old 05-24-2006, 12:12 PM Thread Starter
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thanks for the replys, i think i'll try a hex nut removal tool first, (if i can find one in town) then go to the welding idea.

does anyone know where to get a replacement 10 mm toyota diff drain plug at? If i get this old one out, i can stick a generic bolt it its place until i get a real replacement.

thanks
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post #11 of 31 (permalink) Old 05-24-2006, 12:15 PM
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You can also try to heat up the area around the bolt before you try to loosen.
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post #12 of 31 (permalink) Old 05-24-2006, 12:22 PM
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I'm thinking of getting one of these. Many here have recommended them.
http://frontrangeoffroadfab.com/nfos...b88bf2880930bc

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post #13 of 31 (permalink) Old 05-24-2006, 12:29 PM
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Marlin carries a magnetic one as well....very inexpensive.
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post #14 of 31 (permalink) Old 05-24-2006, 12:34 PM
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I agree with the welding idea. I have done this several times and it works great. Be cautious heating the plug up not to melt anything inside, or ignite the gear oil. Chances of this happening are pretty slim, but just be careful. I have personally experienced gear oil igniting in a diff and it's an ugly scene, smelly and messy too.

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post #15 of 31 (permalink) Old 05-24-2006, 01:18 PM
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You could also use a hammer and small chisel and knock it loose. I had the same issue on my 00 Runner and I ended up letting Toyota do it and they just knocked it loose w/ an air chisel.
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post #16 of 31 (permalink) Old 05-24-2006, 10:14 PM
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post #17 of 31 (permalink) Old 05-24-2006, 10:23 PM
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Mine is the same way. I gave up on it and bought a $10 oil suction thing to put through the fill hole. It got out about as much oil as I had put in before (I measured it), so it seems a good option, and it only took 1 or 2 strokes if I remember.

One thing to watch out for if you buy a replacement plug - the front diff drain is a bigger diameter than all the other drain & fill plugs, even though the front diff fill is the same size as the others.
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post #18 of 31 (permalink) Old 05-25-2006, 11:22 AM
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Quote:
Originally Posted by JoeNobody
does anyone know where to get a replacement 10 mm toyota diff drain plug at? If i get this old one out, i can stick a generic bolt it its place until i get a real replacement.

thanks
The Toyota dealer

I had to replace the rear diff plug on mine, was 3 or 4 bucks. But it wasn't in stock so I had to wait a few days for it to be delivered.
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post #19 of 31 (permalink) Old 05-25-2006, 12:45 PM
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Quote:
Originally Posted by JoeNobody
In my multiple attempts to remove the front 10mm Hex bolt drain plug from the front diff on my 2000 Taco 4x4 I have stripped the bolt up.

I am almost certain that the fluid has never been changed given the condition of the rear and transfer case fluid when I changed them. When it came time to remove the front drain plug I could not get it to come off. Using my huge breaker bar and lots of liquid wrench the drain plug refused to break loose. And after applying enough force I eventually stripped the nut up.

My question is how should I go about removing the drain plug now that itís stripped up? If it was a regular socket bolt I could use a "bolt out" style bolt remover except this is a hex nut style bolt. Do they make removal tools to use in these style nuts?

Thanks
I finally welded a 3/4" nut to the sucker...should have done this a long time ago, LOL It was pretty easy to do. just get a couple solid tacks on it, remove and finish welding. then clean it up so the nut doesn't have any weld boogers to get in the way of a socket.

I tacked the nut on using a 1/2" bolt to hold it on to the plug then touched up spots with a file and Dremel with a grinding wheel so my wench would fit on easily.


Then finish welding and file or grind off the excess on the nut faces


makes things much easier to work with...wrench or socket

Quote:
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Yeah, well, I'm just glad I snagged a few Spector cans before EPA converted them to Sphincters
Quote:
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Lube may be your best friend (depending on location).
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post #20 of 31 (permalink) Old 05-25-2006, 03:00 PM
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That's a good idea for getting the plug out when it's stuck / stripped, but be careful if you're planning on leaving this "modified" plug on your truck (especially if it's on your drain plugs). One reason that these plugs are designed to be flush with the diff casing when they're installed is to minimize the chance of them getting caught on a rock or something when you're off-roading and having them ripped out of the diff, leaving you stranded. The front diff is not bad, but the transfer case and more so the rear diff drain plugs are quite exposed.

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post #21 of 31 (permalink) Old 05-25-2006, 03:20 PM
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Quote:
Originally Posted by gsgallant
That's a good idea for getting the plug out when it's stuck / stripped, but be careful if you're planning on leaving this "modified" plug on your truck (especially if it's on your drain plugs). One reason that these plugs are designed to be flush with the diff casing when they're installed is to minimize the chance of them getting caught on a rock or something when you're off-roading and having them ripped out of the diff, leaving you stranded. The front diff is not bad, but the transfer case and more so the rear diff drain plugs are quite exposed.
Umm, it would be nearly impossible to rip that front diff plug off, LOL
as for the rear, it is already a hex bolt, not an allen.
same with the tranny and tcase.

most of us have beefy skids under everything vital anyways

Quote:
Originally Posted by Teryx View Post
Yeah, well, I'm just glad I snagged a few Spector cans before EPA converted them to Sphincters
Quote:
Originally Posted by Tacoma Jake View Post
Lube may be your best friend (depending on location).
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post #22 of 31 (permalink) Old 05-25-2006, 03:27 PM
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Quote:
Originally Posted by hytenor
I finally welded a 3/4" nut to the sucker...
Awwww...you didn't stay with metric!? What kind of Toyota owner ARE you???



~Miguel

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post #23 of 31 (permalink) Old 05-25-2006, 03:43 PM
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Wont a reverse bolt out work? Die set? Just dont use your hundred dollar set.

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post #24 of 31 (permalink) Old 05-26-2006, 06:04 PM
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Stripped drain plugs

If you strike the plugs sharply with a hammer before you try to remove them, I've found they come out easily (don't murder it with the hammer)

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post #25 of 31 (permalink) Old 05-26-2006, 07:48 PM Thread Starter
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Talking

I'm likin' the welding idea. Today i did the super fast, get it done right now option, and that was to pump out the old crap through the fill plug and replace the fluid.

I'll break out the mig welder this weekend and weld a bolt onto it and pull that bastard out!
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post #26 of 31 (permalink) Old 05-26-2006, 11:19 PM
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Quote:
Originally Posted by miguel4110
Awwww...you didn't stay with metric!? What kind of Toyota owner ARE you???



~Miguel
actually it is a 19mm

that better?

Quote:
Originally Posted by Teryx View Post
Yeah, well, I'm just glad I snagged a few Spector cans before EPA converted them to Sphincters
Quote:
Originally Posted by Tacoma Jake View Post
Lube may be your best friend (depending on location).
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post #27 of 31 (permalink) Old 05-26-2006, 11:19 PM
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Quote:
Originally Posted by JoeNobody
I'm likin' the welding idea. Today i did the super fast, get it done right now option, and that was to pump out the old crap through the fill plug and replace the fluid.

I'll break out the mig welder this weekend and weld a bolt onto it and pull that bastard out!
just make sure to get it centered

Quote:
Originally Posted by Teryx View Post
Yeah, well, I'm just glad I snagged a few Spector cans before EPA converted them to Sphincters
Quote:
Originally Posted by Tacoma Jake View Post
Lube may be your best friend (depending on location).
'00 Excab Tacoma, 2.7, 5sp with a Bunch-o-mods
Inchworm Rock Walkin' Gear
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post #28 of 31 (permalink) Old 04-13-2007, 09:49 PM
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Quote:
Originally Posted by tcmaboy View Post
You can use a reverse twist extractor bit.
I'm having the same problem with mine (stripped front diff drain plug). Is this the extractor you're talking about: http://buy1.snapon.com/catalog/item....re&dir=catalog. It's 13/32", which is slightly bigger than 10mm, so it should be fine, right?

If this doesn't work, I might go the storz route. If not that, then weld. (Dealership wants $95/hr to do the job themselves. AAAAAH!!! Hawaii sucks sometimes!)

Thanks,
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post #29 of 31 (permalink) Old 04-14-2007, 10:16 AM
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Quote:
Originally Posted by Kaistie View Post
I agree with the welding idea. I have done this several times and it works great. Be cautious heating the plug up not to melt anything inside, or ignite the gear oil. Chances of this happening are pretty slim, but just be careful. I have personally experienced gear oil igniting in a diff and it's an ugly scene, smelly and messy too.
I agree, this works excellent.
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post #30 of 31 (permalink) Old 04-14-2007, 10:35 AM
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I had the same thing happen to mine. It had never been off and my truck only had 15K miles. that bitch would not come out and I stripped it.. I used a reverse tap out. Then i went to the stealership and paid like 8 bucks for a new one.

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