Greetings everyone. My latest dilemma: the fill plug on my 5-speed '92 4runner transmission is in way tight. All efforts to loosen it, including multiple soaks of PB Blaster, have been frustrated. The head of the plug is becoming rounded, so I am reluctant to continue the use of wrench or socket to break it free. Short of taking hammer and chisel to the thing, is there a tool or trick I should try?

 

elbow grease and a cheater bar/pipe. you may have to resort to welding on another bolt to get it off or try forcing on a socket. make sure you're using a 6pt socket for taking off bolts so they don't round. definitely replace the messed up plug when you finish up.

 

How about a pipe wrench?

If you can't get it off I think you can remove the shifter and fill from the top.

 

Just ran into the same problem after accidentally draining the tranny. speedometer problem.
Is there any other plug/bolt on the transmission that will give you a good indication of fluid level? or should I just make sure it's drained completely and put in 4.8 quarts. 1990 2wd 22re. Thanks for the info.

 

Fix it and get the fill plug out and replace it with a new one.

Fill tranny until fluid comes out fill plug. It's full.

:wabbit2:

 

After a bit more yanking on the pug, it came off. Thanks for the info.

 

Huhh ... well, the kid's off in the navy; maybe I can hammer one of his english sockets onto the plug and try to reef it off with a cheater bar. Hammer and cold chisel not a good idea to break the plug loose, then?

 

hit mine with a propane torch for a few moments on low and left it overnight. But I think I just got lucky. the rest of it went well. It ended up taking just over 4qts. before it was dripping.

 

Very well. Any one else? I'm ready to try the hammer and chisel to loosen the plug. Speak now or forever hold your peace.

 

Pipe wrench should work.

By the way, these replacements from MarlinCrawler are AWESOME:



Linky: http://www.marlincrawler.com/hardwar...tic-drain-plug

 

There might be success in the imperial sizes, I had luck with a 15/16 and a big hammer to get into my 24mm diff filler plug. 1/16th of an inch might get around your rounded bolt..

 

If you have access to a welder, I find that taking an old nut about the same size as the plug and welding it on top through the hole works perfect. The heat of welding typically breaks the stuck threads loose and the nut gives you a good place for a wrench to get a bite. Of course you'll need a new plug. What I typically find is that the plugs stick due to dirt/grit on the threads, Since it is into a oil filled case, rust is usually not the cause.