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Old 02-27-2005, 01:36 PM   #1
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Stripped Differential Plug/bolt - Help

Any tricks to removing a Stripped differential fill plug/bolt? I can still get a little bit of bite on it, but it ain't budging.

Can I add oil thru the Breather screw??????


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Old 02-27-2005, 01:41 PM   #2
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if its the fill, can you get a beefy pair of vise-grips on it to budge it? can't add oil through the breather knowing how full you are....
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Old 02-27-2005, 02:00 PM   #3
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Tack weld a nut onto it, ratchet it off. Get a new diff plug.

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Old 02-27-2005, 02:26 PM   #4
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Quote:
Originally Posted by colsoncj
if its the fill, can you get a beefy pair of vise-grips on it to budge it? can't add oil through the breather knowing how full you are....
It "should" be empty since I drained it. I do not have a welder to do what waskilly recommended. I was thinking of adding 3 quarts (if possible) through the breather screw just to drive it to a mechanic to have them deal with the stripped bolt.

whadaya think - Not a good idea?
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Old 02-27-2005, 02:30 PM   #5
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Yep, get some fluid in there however ya can and then get that stripped one out and replace it. You might possibly try the Craftsman stripped bolt removers, but I don't know if they have one that big.

Good luck and make sure to update the thread when you get the problem fixed so others can do the same when they have the same dilema.

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Old 02-27-2005, 02:36 PM   #6
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try using a real good epoxy rather than tack welding
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Old 02-27-2005, 02:54 PM   #7
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Someone on Pirate had mentioned using a cheap socket with JB Weld for stuff like this.
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Old 02-27-2005, 03:37 PM   #8
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I reallly dont think JB weld or epoxy would work.

First try a few different sockets, 6 point and 12 point. I've even tried a different brand and it fit better. Also try a standard size socket. Or try taking a socket and hammering it down on the bolt head.


Or you can use a torch (propane can be had cheaply) to heat the bolt up and remove it.


If all else fails, go ahead and fill it up through the breather plug and then take it into the shop.
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Old 02-28-2005, 04:37 AM   #9
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Did you get the fluid in there? Let me know if I can be of any help since I'm close to you.

As a reminder to everyone else. Always remove the Fill plug before you remove the Drain. That prevents problems like MD is going thru. Sorry man!!
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Old 02-28-2005, 05:09 AM   #10
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This is a good case for the use of air tools.
If you hammer on the next smaller size socket and use a decent airgun, it should zip right off.
If you don't have a compressor and air tools, rent them.


Welding a socket on the bolt works very good too but you need the skills or need to know someone who does to do it.
Worst case you can have it towed to a shop and they will do it for you.
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Old 02-28-2005, 05:19 AM   #11
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Sears has a set of tools that may help with your problem?
http://www.sears.com/sr/javasr/produ...id=00952166000
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Old 02-28-2005, 06:30 AM   #12
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Quote:
Originally Posted by westca707
Sears has a set of tools that may help with your problem?
http://www.sears.com/sr/javasr/produ...id=00952166000
Those are nice but the biggest one is for 19mm, that fill plug is 24mm. There is a broken bolt extractor that might work but you would need to drill a hole through the fill plug first. http://www.sears.com/sr/javasr/produ...seBVCookie=Yes The worst thing about that would be the metal shavings that would get into the diff as you drilled the hole. You could try filing down the sides of the fill plug to the next smaller size socket and use heat on the plug first. Tack welding a nut on there would be my first choice for getting out of this mess.
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Old 01-22-2011, 06:25 PM   #13
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I'am having the same issue. I know this is an older thread, but making a new one didn't seem nessesary..

My rear diff plug is rounded off pretty good. I guess someone didn't want any one else changing the rear diff fluid...

Good news is I was able to "break loose" the drain plug with a 24 INCH BREAKER BAR!! jeez man...why so tight?

Funny thing; every where I go I ask for a rear diff fill plug and they tell me they can't get one...wtf. Montgomery mentality for you.

I was going to torch it but I gotta get some propane, I have mapp gas but I don't know the melting point for alluminum is and I know mapp is hot, I dont feel like re-threading a rear diff.

I gotta get a plug first, anyone know a part number by chance?
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Old 01-22-2011, 06:35 PM   #14
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Quote:
Originally Posted by Vukodlac View Post
I'am having the same issue. I know this is an older thread, but making a new one didn't seem nessesary..

My rear diff plug is rounded off pretty good. I guess someone didn't want any one else changing the rear diff fluid...

Good news is I was able to "break loose" the drain plug with a 24 INCH BREAKER BAR!! jeez man...why so tight?

Funny thing; every where I go I ask for a rear diff fill plug and they tell me they can't get one...wtf. Montgomery mentality for you.

I was going to torch it but I gotta get some propane, I have mapp gas but I don't know the melting point for alluminum is and I know mapp is hot, I dont feel like re-threading a rear diff.

I gotta get a plug first, anyone know a part number by chance?

What vehicle? Specs?

Is the fill plug the one that is stripped? Weld a bolt to it and that should let you get it out.

Worst case, you can fill through the breather plug hole once you pull the breather plug.


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Old 01-22-2011, 06:43 PM   #15
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Yes, sorry about that I should know better.

97 4 Runner, SR5, 3.4L

Yes, its the fill plug on the rear diff.
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Old 01-22-2011, 07:12 PM   #16
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I deal with these Jiffy Lube "signature service" butcher jobs all of the time. I just air hammer an edge of the fill plug. The vibrations from the air hammer help extremely well with over tightened plugs. Works everytime and only takes a couple seconds!
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Old 01-22-2011, 07:19 PM   #17
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Quote:
Originally Posted by Vukodlac View Post
Yes, sorry about that I should know better.

97 4 Runner, SR5, 3.4L

Yes, its the fill plug on the rear diff.
Fill plug
90341‑18006

Gasket for fill plug
12157‑10010

Drain plug
90341‑18057

Gasket for drain plug
12157‑10010

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Old 01-23-2011, 06:29 AM   #18
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Thanks for the part numbers!

Lex; Would a 125psi compressor be enough to do the job? I have air tools but they are an autozone tradespro special.

I guess in that case I would have to make an edge, since the plug is pretty much rounded off.
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Old 01-23-2011, 06:40 AM   #19
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I'm sure 125psi would suffice, especially if the air hammer is a little guy. Yes you will have to dig into it and of course on an angle to go in a counter clockwise direction. I have an air hammer bit that's like a half moon/tanto type tip on it (there might be a technical name for it), but just a regular chisel bit will work too. Wear your safety glasses and watch out for your knuckles when it does break free!
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Old 01-23-2011, 07:06 AM   #20
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Alright cool, yeah it a smaller air hammer and I have bits for it. I've never used it, lol. But yeah I get what you mean.

I'll let you know If I could break it loose. That way we have some info for the next gent that has this issue.
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Old 01-23-2011, 07:06 AM
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