Front diff replacement plugs?

Welp, like many on here, despite using penetrating oil and some heat, I managed to strip the 10mm alan key hole in the drain plug of my front differential.

I did my rear diff, manual tranny, xfer case all fine since they use normal hex head bolts.

For the front diff I took the skid plate off, cracked the fill bolt, but when the drain bolt came, nothing would budge it. It had been soaking in penetrating oil over night, and I ended up trying heat, but no luck. Eventually I went too hard and stripped out the alan hole.

Looks like I'm going to have to find a place to weld a bolt onto it so I can get it off.

Long story short, does anyone make a corrosion resistant and most importantly regular hex bolt headed replacement bolts for the front diff?

Thanks!

 

Yes they make them in both square and hex head in 300 series stainless and high pressure plastic.
I would replace it with the OME plug and put never-seeze on it when installing, but that is up to you.
Also I would not wield anything on the old plug to try and remove it. I would drill a hole in the plug and use an easy out, but that too is up to you.
Here is a link
https://www.google.com/#q=npt+plugs

 

I'd tap it a bunch of times with a hammer after soaking it more with penetrating oil, then stick a fat easy-out in the stripped socket and wrench it off.

Have a new plug on hand to replace it.

 

Thanks! You know what size and threads the toyota one is? The OEM plug is hex head seemingly for no good reason, so I'd rather have something that cant just strip when 30 ft lbs are applied.

As for the welding, the vast majority of advice in the stripped plug threads say just welding a bolt to it is the easiest but I'll explore all options. Thanks!

 

Regular hex bolt head, with a magnet.

http://www.magneticdrainplug.com/Automotive_Drain_Plugs/AP24.html

 

Sorry I do not know the size. I would think Toyota parts could tell you.

 

Use a tool like this to get the old one out. Would try to avoid welding the plug if at all possible. Don't want too much heat getting transferred into the diff.



I had to use a tool like that to get mine out Worked really well though.

 

I would weld something on the plug before trying an easy out if it's siezed an easy out won't get it out welding a bolt or nut on there won't transfer enough heat to hurt anything especially if it still has fluid in it good luck with the repairs

 

Heat it with a torch. Let it cool for a few seconds and try it again.

I had the exact same problem. I welded a bolt to the plug and it came right off. The heat from the welder helped loosen the plug.

When my dad had the same problem as I did, we just used a torch to heat the plug rather than weld a bolt to it. The torch heating and cooling the bolt a few times loosened it enough to come right out.