kyle_22r

anybody know the best way to remove a seized diff fill plug? the paper thin surface of the nut on my front diff is stripped(damn you, previous owner) and it doesn't want to come out, no matter what i try to do

isn't there some kind of kit that drills a hole and is able to extract these kinds of things?

4RUNR

Use a cut-off wheel on the dremel and make a groove for a big flat-head screwdriver?

kyle_22r

i went to the store and got some pb blaster. i'm gonna try soaking it in that stuff for a few days. if i cant get it out then, things might have to get drastic(blowtorch, impact wrench, hammer drill etc)

its2slo

just remeber, never take no for an answer!! it hasnt failed me yet.

Arnold

Try using a hammer and chisel to back the plug off. That's how I got the one on my dad's Toy off. You might want to think about upgrading to the low profile Camry drain plugs which use an Allen wrench to tighten/loosen 'em once you get yours off. You're less likely to strip and over tighten these plugs.

scott.475

I wouldn't try the Dremel method mentioned above. If you really buggered it up with that you would really be in trouble!

They do make kits for extracting dorked up bolts, they are usually called "EZ-Out"s. You drill a hole, then insert what is basically a reverse threaded bolt and tighten and screw it into the hole, which removes the plug.

Have tried biting into the remaining head with a pipe wrench? A useful tool, the more pressure you use, the tighter it grips!

kyle_22r

i'll have to try that pipe wrench method. i'm not concerned about recovering the plug one bit, since i have 3 brand new ones from the factory that i found in under the seat still in their plastic bags. i'll definitely get those low profile plugs for the drain holes eventually, though

MTL_4runner

Definately hit it with some PB blaster and let it sit over night.
Then go after it with some vice grips and a hammer if necessary.
If it still won't budge use a torch to heat and cool it several times.
Should be enough to losen it but some are quite difficult.

95_4X4Runner

I'd think a propane torch would be good enough for heating it up, that and a BFH with vise grips, and you'll get it off. It's us against them, and we always win...

Fink

One word...jackhammer

But I would be more inclined to do the PB Blaster or Liquid Wrench soaking trick before I go to anything drastic.

Fink

keisur

I had the same problem and went as far as a torch to heat it up and a pipe wrench and a bottle jack to grip and turn it with some force. NO DICE. I actually just drilled a hole in it and tapped it 1/2-13 and plugged it with a nylon bolt and some telfon tape until I pulled my 3rd member last august. I them gave it a couple taps from the inside and then used an EASY OUT the size of the 1/2" hole on an air impact wrench and it spun right out.

I then had the bright idea that I could have just welded a 1 foot x 1" wide x 1/4" bar to it and then I probably could have broken it loose that way. Problem with that is if it broke loose, then you gotta cut the bar off so you can rotate it.

anyway, my suggestion would be weld a bar to it if you have access to a welder or drill and tap a hole like I did and just wait until you pull the 3rd for maintenance.

good luck.

EASY OUT KIT from Harbor Freight for $9.99 - Click the Pic below.

toy283

Weld another nut to it. The heat and a new wrenching surface will spin it right out.

kyle_22r

might have to drive it down into the shop tomorrow and try welding someting to it tomorrow. i have access to a welder at school(being that i take welding full-time) and i'm sure that could work if i don't have luck with the pipe wrench

jjdeneen

357 magnum

9mm

38 special

if those dont work you can try....

30-06

308

30-30

Shane

Welding a nut to it should work fine, always has for me. If you get real desperate you could hit it with a .50 cal, the resulting hole should be around the right size and all you'll need to do is put some threads in it...

kyle_22r

well, looks like i'm gonna do some welding tomorrow

pipe wrench + pb blaster didn't work. that thing is on there GOOD. i'll have to go find myself about a 16 or 18mm nut and weld it on there, and try to bust it loose

i take it i should drain what's in the diff before giving this a shot, right? i'd assume it's safe to drive with no fluid in front diff as long as the hubs are unlocked

Glenn

Oh, I suppose you could drive without any gear lube in the front diff with the hubs unlocked, but what if you STILL can't get it off? You'd really have a hard time filling it from the drain hole.

mt_goat

38 special???? that won't shoot its way out of a paper bag
Go with the magnum!

mt_goat

Well I am just guessing here, but I would think you could tack weld a nut onto the plug without draining the fluid. Just go slow and allow cooling time between the tacks. In fact it might be more dangerous to have the oil drained because there would be more air and fumes in the diff to explode, plus the oil will act like a heat sink. Either way there is danger.

kyle_22r

i'm not too worried about it. the axle is in pretty good need of a rebuild, but i don't have the cash right now

i was planning on going wheeling yesterday, and wanted to make sure i had gear lube in the diff(it pisses out past the seals since they're pretty much shot), and that's where the problem started

mark my words, it's GONNA work