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How to remove stuck front differential drain and fill plugs

Discussion in '2nd Gen. Tacomas (2005-2015)' started by loredoarturo, Feb 20, 2012.

  1. Jul 30, 2013 at 7:23 AM
    #21
    Bearcoatoffroad

    Bearcoatoffroad Well-Known Member

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    In fact, google "stuck transmission drain plug" and millions of forum hits come up for all types of cars and trucks.
     
  2. Jul 31, 2013 at 7:27 AM
    #22
    Eldub

    Eldub Member

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    So what would you guys recommend torquing the front diff drain plug to, if it should be less than 48-lbs?

    I don't want to wrestle with this thing on the next oil change and although it is too late for me to add antiseize since I just changed the oil, I can go back and torque it to a lower value.
     
  3. Apr 24, 2014 at 7:35 PM
    #23
    lyodbraun

    lyodbraun Well-Known Member

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    Is there any way to change out the plugs to one that will use a socket and not the Allen style ? Like on the rear and transfer case..
     
  4. May 31, 2014 at 10:22 AM
    #24
    Tacomanimal

    Tacomanimal TacomaWorld

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    I know its an old thread but people still go back to it in time of need, like I just did. Drain plug stuck. After reading this I just decided to use my leg strengh pressing on the rachet handle, and pop, it finally unstuck! Always be cautious when this much force is involved.
     
  5. May 31, 2014 at 11:31 AM
    #25
    DJB1

    DJB1 Well-Known Member

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    I deal with this all the time at work because excavators and dozers have similar drain/fill plugs on their final drives. A co-worker who is older and wiser than me showed me how to get those phuckers loose:

    1. There's usually crud camoflauged by rust that prevents the allen socket from going all the way in. Scrape out the hole in the center of the plug with a pick or small screwdriver and clean it with compressed air or brake-clean.

    2. Make sure you have the correct size hex socket and gently tap it all the way in with a hammer. I don't use allen keys because it's too hard to get leverage. An allen socket and a 3/8" drive breaker bar work way better. I have one that's about 10" long and it's the perfect tool for the job. I would not use a 1/2" breaker bar because it's too easy to strip the plug out.

    3. Stick the breaker bar in the socket. Put a little bit of force to it, about what you'd need to loosen a normal bolt that is not seized. Rap the head of the breaker bar with a hammer while you have loosening force applied to the breaker bar. Make sure it's a ball-peen or hand sledge-only a metal hammer will work.

    Sometimes it takes 15-20 minutes of work to break the drain plug loose. Just be patient and try not to strip it. Even if it takes you 3 hours, that's still better than stripping out a stuck drain plug. This trick works even on machines at salt refineries off the Great Salt Lake. I've tried it with or without penetrating oil and it didn't seem to make a difference. But if you want to smell like a machine shop for a few days, be my guest.

    Be patient and wear safety glasses. You don't want to be laying in the driveway bleeding from the eyes with no oil in your differential and a stripped out fill plug.
     
    po35042, PzTank and CMD-KY like this.
  6. May 31, 2014 at 2:35 PM
    #26
    monkeyface

    monkeyface Douchebag, or just douche if we're friends

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    Those 10mm Allen front diff plugs can and are a problem, just don't torque them down too much when you reinstall. I think the factory torque specs are overkill in both of the differentials and transfer case. I don't torque them down much at all and never had one come loose or leak. I don't use a torque wrench, just snug them up and give a teeny little bit extra.

    And BTW, use a 6-point 24mm or 15/16" socket for the transfer case and rear diff drain and fill plugs, don't use a 8-point. Them devils tend to strip with an 8-point socket or wrench.
     
    CMD-KY likes this.
  7. May 31, 2014 at 3:44 PM
    #27
    ecoterragaia

    ecoterragaia Everyone lives downstream.

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    I'm in this boat with my front diff drain plug. I'll follow the suggestions posted above, and probably get a new plug while I'm at it. Thanks!!
     
  8. Jan 10, 2016 at 5:08 PM
    #28
    pidgeball

    pidgeball Active Member

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    Good advice. I've used a similar approach since I was young. Usually works, but today I wound up using penetrant, the torch, and the 3/8" breaker and all I have to show for it is a busted breaker bar. Craftsman, sheared the square drive in half... I'll let the dealership get it off.
     
  9. Apr 28, 2018 at 12:51 PM
    #29
    Benny123

    Benny123 Kid from the late 70s

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    Appreciate the advice here. I have a pretty rusted lower drain. Tried breaker bar with heavy load (1/2 breaker started bending), wire brush, penetrating oil, and a cordless impact. No dice. Fortunately oil looks good out of top plug, as I just had CV axle put in and I think they added/changed some. Tea colored & clear. Thinking I need to try some heat and atf/acetone mix, possibly tapping the edge with chisel and hammer. If that doesn't move it, I guess I need to have a shop do it.
     
    Last edited: Apr 28, 2018
  10. Apr 29, 2018 at 6:48 AM
    #30
    GREENBIRD56

    GREENBIRD56 Well-Known Member

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    I've read this twice and haven't seen a reference to the type and size of the plug threads. Has anyone with new plugs checked them out? I would guess they are some sort of British straight pipe thread. If so - there is probably an alternative.
     
  11. Apr 29, 2018 at 10:13 AM
    #31
    Muddinfun

    Muddinfun Well-Known Member

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  12. Apr 29, 2018 at 2:09 PM
    #32
    Lester Lugnut

    Lester Lugnut Well-Known Member

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    I've never dealt with 4WD, but I've drained/refilled a number of rear differentials and find that it helps to back the vehicle up on ramps or elevate however you like; then get underneath with a VERY log breaker bar. Has always worked.
     
  13. Apr 30, 2018 at 1:58 PM
    #33
    GREENBIRD56

    GREENBIRD56 Well-Known Member

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    Here is the first reference I found on the web for a hex head Metric plug...
    metric plugs - Hex Head.jpg
    Probably have to buy the washer from Toyota...........
     
  14. Apr 30, 2018 at 4:00 PM
    #34
    Benny123

    Benny123 Kid from the late 70s

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    Do you have a link for these? And any idea what size we need for the diff drain?
     
  15. Apr 30, 2018 at 4:35 PM
    #35
    NCtaco13

    NCtaco13 Well-Known Member

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    I know sometimes when i used to work on helicopters if a bolt was stuck we would tighten it more and sometimes that broke it loose and we could take it out
     
  16. Apr 30, 2018 at 4:51 PM
    #36
    GREENBIRD56

    GREENBIRD56 Well-Known Member

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    Just Google - "Metric Hydraulic Port Plug" and a variety of vendors will appear.............. When I checked there were several different ways to go, the hex shown above - the factory stock style - some with seals and some that would require a gasket. I haven't had mine out - maybe I ought-to on general principle - but it shouldn't be hard to identify when you can measure the threads.

    It "looks like" an M24-1.50 will be the size, but until I have one in my hand (and a thread gauge) or someone else has the info, its only a guess.
     
  17. Apr 30, 2018 at 4:53 PM
    #37
    Extra Hard Taco

    Extra Hard Taco Survivor of the winter of misery and death.

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  18. Apr 30, 2018 at 6:12 PM
    #38
    winkel

    winkel Well-Known Member

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    When re-installing the plugs, I always use Teflon tape. I wrap them up pretty heavily then don't torque the crap out of them when re-installing them. The Teflon tape gives them a little friction too so if they would think about coming loose, they won't vibrate out. Just check them a few times in the following months to make sure they've stayed put. Min always come loose with little extra effort.
     
    po35042 likes this.
  19. Apr 30, 2018 at 6:49 PM
    #39
    L J

    L J Well-Known Member

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    Just thinking out loud here. Most folks use a pump to get the fluid in. If you have a pump at your disposal you could use it to suck the old oil out. Not a perfect solution but at least you can get it done if you’ve stripped the drain plug. Changing most of the oil is better than changing none of it.
     
  20. Nov 28, 2018 at 3:46 PM
    #40
    Eisenhower

    Eisenhower Well-Known Member

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    Has anyone found an alternative hex plug for the front diff? Does the M24x1.5x14 magnetic drain plug work?
     

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