Differential Drain Plug-Won't Budge

Is it me or is there something inherent with the differential drain plugs that causes them to become extremely hard to remove? I snapped a 10mm allen socket trying to remove the front diff drain plug. Fill plug was easy. I put some PB Blaster on the drain as well-no luck. Who the heck put these on so tight? Any ideas or tips on how to remove these?

 

Sounds like it was over torqued at some point. It’s easy to do on the front diff.

 

Make sure the fill opens first. I never had issues on Toyota front diffs.

 

Don't use impact gun. Tap 10mm hex in lightly with a hammer and then apply steady counterclockwise pressure with breaker bar. G.L.

 

I did that. Nothing. Snapped the first 10mm, second one is not budging with breaker bar. It's like the shop who did the last service way way over torqued this this.

 

Fill loosened without issue. Rear dif was piece of cake. Maybe more heat soaking on front causes the plug to seize?

 

We actually cut a piece off of an old chisel to get the allen. Then the bolt stripped and I noticed it actually has a “Star “or torx on the bolt and then an Allen on the inner part of the bolt. But ended up sucking it out the fill with a tube.

 

I'd spray over it with PB Blaster or other penetrant oil and sleep on it. It will open up tomorrow. I did my on cold diff and not sure if it makes it easier to remove when case is cold or warm after drive. If all else fails - take torch to the case and heat the hell around drain plug. Heat shock will certainly release the bond or if some genius used Red Treadlocker on plug, then heat is only way to turn it.

 

Breaker bar and pb blaster or similar will do it. Make sure it stays soaked

 

It’s very common that the front drain doesn’t want to come out. Replace it with the Lexus one.

 

I'd get a manual impact.

Helps a lot not to strip anything.

This is the one I have though it looks to be not available now.

TEKTON 3/8" Drive Impact Screwdriver Set (7-Piece) | 2905

https://www.amazon.com/gp/product/B000NPPATS?ie=UTF8&th=1

I use it for anything on my boat that doesn't come out by hand.

 

Another tip that has worked for me (I rebuild a lot of old worn out vehicles):

1) Thoroughly wire brush (use some elbow!) the whole area around the plug to get the rust and crust off
2) Heat the plug and immediate vicinity with a propane torch. Don't make it glow, just get it smoking a little (note: you'll be changing the fluid anyway, so don't worry about wrecking it)
3) Remove torch and touch a dinner candle or birthday candle all around the circumference of the plug where it meets the case. The wax will wick into the threads.

Then use a stubby socket hex bit (short so less likely to break), tap home with a brass hammer to make sure the bit is fully set in the plug, coerce with ratchet or breaker bar of your choice. Keep pressure with one hand against the back of the ratchet or breaker bar to ensure it doesn't pull out of the plug.

If this doesn't work, the final step is:

A) Weld a nut onto the drain plug
B) Remove with socket and breaker

Jason

 

Great advice. I had our company mechanic look at it. He snapped his Matco 10mm socket and then got it out with a chisel. It's just incredible these become so darn stuck. Thanks for all the advice. I think the Lexus alternate part is a good idea going forward.

 

I usually just hit the front diff drain plug squarely and hard with a 32oz ball peen hammer a couple times without the 10mm hex in there. The "shock" releases its death grip. It will still be very tight. Works 99% of the time. Otherwise, carefully chisel without damaging the differential.

 

Thanks. How hard are you hitting the plug?

 

Well, difficult to say but pretty damn hard. I bring it back behind my ear, kinda like a quarterback's throwing motion if that makes sense. You need to hit as hard as you can and stiil hit the target. If your doing it on the ground you may not have enough room to swing it hard enough, but I cheat and use lifts..

 

Got it. Hate to miss and knock off a chunk of the diff.

 

Yeah, don't do that...

 

well I was doing the flame torch plug , if it is locked up ...used the water in the ice of the socket/wrench ,,,.

 

Interesting. I never heard about that bit with the wax.

 

Farmer trick. Works well.

 

Yes, get the Lexus 90341-24016 front diff drain plug with the hex head to replace that Toyota allen head 90341-24014.

 

Will the wax wick past the copper crush washer?

 

Doubtful, if it did then gear oil would be leaking out.

 

Have you tried this? They're freaking magic and can unstick things that a breaker bar can't.

 

Really? I will have to look for one of these.

 

These are amazing for Honda rotor screws.

 

Its the one and only thing I use on the boat. If the screw doesn't loosen with a screw driver by hand I use the manual impact.

Will save you a lot of headache with stripped screws. And its cheap.

 

oh boy, these give me bad memories. Mostly because I must be directionally challenged understanding which way to set it. I’ve ended up hammering it with it set to tighten on more than one occasion. That’s a me problem though lol

 

The one I have has markings which way. Even if it is set to the wrong way it won't hurt anything. It just won't help either.