Is it Karma??

It never seems to fail. If I have 6 plugs to remove, there are always 5 that will let go.....but the 6th one has to be an SOB!!!!!

Setting up to change fluids in the F&R diffs and the Xfer case. Sure enough, Rear diff lets go of the plugs with some effort, Xfer case follows suit. Front diff, the fill plug lets go with more effort, but the friggin' drain plug won't budge.

I've scraped all the debris from around it, hosed it with PBlaster, strained my groin pullin' on the 1/2" ratchet, not enough clearance for the breaker bar, beat it with a hammer, hosed it again with PBlaster, tried the 1/2" ratchet again. Now, the GD allen is beginning to round............. So, I quit for now.



I do not have a welder nor an impact gun. I'm up for suggestions to remove this GD plug.
I'd like to kick the individual's A55 for specin such a STUPID fastener........

The $10 question. Is/are there plugs for the fill and drain on the front diff with a hex (not an allen hex)? If so, where to obtain? Anyone know the thread size on these two plugs.

I'm pretty sure I'm not the 1st to howl about the plugs on the front diff.

 

The front drain always takes me some effort to crack free. I have to use a breaker bar on it with a 10mm hex socket. No issues with it rounding out. There is a replacement with a 14mm hex on it. Let me try and dig it up for you.

 

https://www.tacomaworld.com/threads/front-diff-drain-plug-alternate-oem-part.604989/

Lexus part number

Toyoya 90341-24016 PLUG, STRAIGHT SCREW

90341-24016

 

Randy....does that fit both the fill and drain?

I'm thinking I'll be making a trip to the 'Yota dealer this afternoon.

 

No, it only fits the drain. Typically that's the plug people have issues with.

 

Only fits the drain.

Strangely enough, you can’t get that plug from the Toyota dealer. I had to get mine from the Lexus dealer.

 

For removal of the stubborn one, a sharp flat chisel and a hammer typically work pretty well. Or a special extractor tool.

 

Nuts..... nearest Lexus dealer is about an hour drive one way.

Any tips beyond Brute Force and Awkwardness to remove the GD drain plug????

 

Sorry to hear about your troubles brother.....I would try some heat on the bad boy! Use either a small propane torch or if you have it mapp gas. If not its not to hard to pickup one at your local hardware store without spending to much money.

Worth a try for sure....

Let us all know how you make out.....I'm sure other folks will benefit from your experience for sure.

Stay Safe and Work Smart!

 

Haven't tried my MAPP gas torch. Typically, I use that for sweating copper pipes together.

I assume to heat the surrounding area on the diff and not the plug.

You know, I don't mind doing my own work, but this kind of crap is really, really frustrating and aggravating.

 

The hammer and chisel will get it out. Use the chisel to make a cut in the outer edge. Then hammer on the chisel in the counter clockwise direction of rotation. It's the same way you remove ignition switch break off bolts.

 

I have a cold chisel and a 3 lb hammer, a 2lb dead blow hammer, a 16 oz claw hammer and a 12 lb sledge.

Swingin' any of these will be clumsy at best.

Ok, I'm off to 'Yota. I'll test the part counter to try for options. I'll post anything new and positive.

 

For sure....
Yah..simple process of expansion and contraction. Heat up the surrounding area and it might just be enough to brake free the plug. At this point you've nothing to loss. Unless you want to call a Priest...

 

I've had good luck with EZ Grip on rounded allen head screws..

 

What happend exactly that makes this Karma? Did you not help an old lady cross the street or give money to a homeless person? Why are you thinking this is due to Karma? Have you been a bad boy and are feeling Karma played a role somehow? Do tell

 

Left hand drill bit, if that doesn't grab it, pound an EZ-out into the hole you made and work from there. Not pretty but also will absolutely take care of it at one of those two steps.

 

Thanks guys.

Well, the parts guru at the local 'Yota was very helpful, but we weren't able to glean any fruit. He searched all the 'Yota 4WD for any matching information.....all goose eggs. It is kinda hit & miss. Their system will only list part number with a general part name. No details for threads.
They have a consistent problem with the front diffs on all 'Yotas. Seems this is a common part with a common issue and no resolution.

The previous mentioned plug is a Lexus "ONLY" item. It doesn't surface on the 'Yota part database.

So, I ordered a front diff drain plug and all the gaskets for F&R diffs, Xfer case and crankcase (oil drain plug). Everything will be in tomorrow.

Got home tried the torch approach.......no love. Invoked the name of God a couple times......no help.

Tomorrow, after I gather the parts, I'll cold chisel that bugger off. If that fails, then I'll find an EZ Out and matching drill bit and prepare for a mess.

The Karma background is much too long to detail here. You guys don't need all my sorted history.

 

get some air in a can. heat the area around that plug well, hit the plug with air in a can upside down spraying it as liquid. it freezes shit. loosen plug.

 

I've had to use a chisel and hammer approach before as well, IIRC there's also a replacement available from Toyota that has a 12mm internal hex rather than the 10mm internal hex.

I've tore one drain up by stripping the 10mm hex, and another by breaking off a 10mm allen socket in it, got one out by chisel and the other by welding a nut on it, honestly I think the heat did more than the nut though as when I put the socket on it it came off easier than I was expecting.

In the end I replaced the front diff drain with one of those and got a Snap-On 12mm allen socket and I can crack her loose without issue now, first time I've seen the Lexus external hex plug.

Instead of chiselling at the flat hit the edge of the drain plug.

A good thing to keep in mind is the copper gasket is a crush washer and is spec'ed as "one time use only" meaning torquing down on it a second time will just make it even harder to get off next time.

Always replace the crush washers, don't reuse them.