Cross threaded differential fill plug!

I did the same, I took it to a mechanic I didn't want to cause anymore damage then I already did, let the pros fix it its worth spending a few dollars wasn't that much

 

So I thought I'd do a followup for anybody that this happens too. I overtightened my fill plug. Got the old one out and bought a new one. Re tapped the threads (Marlin Crawler). Trick here I learned is to fill the gaps with loads of grease to catch shavings that may occur. Worked great, came out with a few. New plug threaded great but still had a slight leak. After multi-state trip I took a look to see how much had leaked out. Lost about .2-.3/qt. Bought another qt and put teflon tape around threads this time and cleaned cover as much as possible. Coated with flour to make it easier to tell if anything was leaking. So far after 1 week and about 100 miles in 100+ degree temp all is good. No leaks.

 

You were leaking out of the fill plug or drain plug?

 

Never had an issue not using a torque wrench on any drain or fill plug....

I think it’s been mentioned here a few times but you use a 3/8 ratchet,, choke up to the socket and get it as tight as you can.

 

That's what I'll be doing from now on. Last time I torqued my transfer case drain plug I overtightened it just a bit and have a tiny leak. Guess my torque wrench was slightly out of spec.

 

Drain plug. I actually followed up again with some gasket sealer and have had no leaks for about 6k miles so far.

 

Roger that. I might try the teflon tape first to see how that works. Which gasket sealer did you use?

 

I wouldn't use teflon tape, you don't want that clogging any orifice or passage in the differential. Better off going with a PFTE tread sealant, such as

$26 Permatex 80633 Thread Sealant with PTFE, 16 oz. , White

this.

 

never been so scared to change diff fluid in a truck before reading this.

 

It's a 15 minute job bub

 

if that. i just don’t know why tacomas would have an issue with stripped threads? never been a concern with my f150. is it something about tacomas or user error?

 

The drain plug can become tough to remove, as long as you have a welder it's not an issue. That 10MM hex plug was designed by satan.

 

There’s an alternative, at least for the front diff drain..
https://www.tacomaworld.com/threads/front-diff-drain-plug-alternate-oem-part.604989/

 

Well I wouldn't have used so much of the tape that it was hanging into the diff ... but I was worried about the tape potentially having issues with the heat. Thanks for the link to the thread sealant. Just ordered.

 

Just curious what size tap is needed to chase the existing threads on the diff drain/fill holes?

 

This...

 

I'll be doing this next weekend.

I bought a new torque wrench because my other new cheapo from scAmazon broke a bolt on my transmission shifter assembly (always the last one you put on.). Finished front diff, transfer case, and was putting in the plug on the rear diff and it wouldn't snug down... I wasn't cranking it very hard either. Everything was set to spec. It's not leaking at the moment...

I went to the dealership for new drain and fill plugs and gaskets/washers before I started.. Should have looked in the bag when I walked out. Guy didn't give me a rear diff drain plug replacement and I didn't realize till I had drained so I went with the old one and a new gasket/washer. Truck is 20 years old and 235K miles... decided to go with the old one and a new gasket...

I didn't hear it snap, I didn't hear it break... I just got it to the point I'd want to torque it to spec, did so and it just kept spinning. Tipped me off when the mother would spin and get tighter and then loosen a bit and then get tighter again...

Damn shame... always something.

 

I ended up just grabbing some liquid gasket and it’s not leaked since.

 

Thanks FFMast, good call.

Just ordered some Permatex High Temp liquid gasket, (-54 - 343°C). If I can't thread the replacement on easily and I have to tap or re-thread I'll try some of that first & with the tapped thread. Providing I can get the plug off to begin with.

 

I did do a re-thread with the next size up plug. Got my tap from Marlin Crawler. I greased it up real good first to catch shavings and that worked real well. Then I put the high temp gasket sealer on there. I’ll try to find the tap and let you know what size I used.