Front diff drain plug stripped fml

It's had pb blaster sprayed for the last 4 nights and let sit. Got nothing out of a 2 foot breaker bar. Ran the impact on it (cordless craftsman 1/2 in), and that stripped the bolt. Tried a chisel counterclockwise and nothing. Most of these attempts got some heat from the torch but nothing excessive. I guess my next move is hammer an 11mm hex head in there?? The fill plug is good to go, just getting whooped by the drain plug. Any suggestions

Drain plug:


Fill plug:

 

Can't help, but that is such a bad design for something exposed to water, salt, etc. There really ought to be a 1/2" nub.

 

Need an easy out

 

Weld a nut on and impact off. Easy peasey lemon squeezy.

 

It's happened plenty times before, there is an alternate external hex plug that can be used.
https://www.tacomaworld.com/threads/front-diff-plug-help.759549/#post-27076030

 

X2

 

A word of advice in the future, take the fill plug off first. if it was the other way around, where the drain came out fine and the fill was stuck, you'd be in a rough situation. All the fluid would be drained without a way to get any more in. (quick edit: I see that you did get the fill out first, good thinking)

I welded a nut on the outside of that face and have been using it since. I tried a torch to no avail, but the rapid heating of welding got it right out. Bought the HF titanium 125 specifically for this job, then proceeded to use it to build skids.

 

Need to keep that heat on there for at least 30 seconds, soak that nut in the blue flame. Then use the easy out. Then onto welding a nut on.

 

If you are determined to pound something in there “just to see”.

I might go with a torx.

Other than that, weld is the best option.
I don’t weld, but I have a brother that does. He’s saved me more than a few times.

 

pb blaster doesnt do anything due to the drain plug gasket, it keeps it out. Welder is most likely your best bet. you could also pump the old fluid out through the fill port and then refill.

 

30 seconds with a propane torch will increase the temperature by a very minimal amount, there is just too much mass in the front differential and a propane torch doesn't have a high heat flux.

Whereas the welder is melting metal on the surface almost instantaneously. calculating the heat flux of a welder is kind of a complicated problem, but its way more than a propane torch haha

 

Pipe nipple extractor if welding isn’t an option.
https://www.homedepot.com/p/Husky-P...V2P_jBx27KQUMEAQYAiABEgK9gPD_BwE&gclsrc=aw.ds

Same exact thing happened to me last weekend.

 

Looks like the the hex bit part is already stripped out, bummer.

Welding a nut on will most likely be the only way.

One more attempt before you do that. Looking at you picture, try going at it with the chisel but with a different angle of attack.

2 pictures, first your angle of attack. Second, try that being careful not to hit the differential, just hit the plug.

 

When you applied heat, you didn’t apply heat directly to the drain plug, right?

 

Tried the extractor, made a pretty circle. Think I'm gonna find someone who welds now.

 

Use a bigger extractor on a screw knocker in an air hammer. It would have been easier if you initially used the proper hex in the screw knocker, and I was going to suggest pounding a bigger hex in using a screw knocker, but it looks like it's too late for that.

Screw knockers (sometimes called "old man" (I don't know why)) have been used in the aviation industry for decades when it comes to stuck fasteners. They are quite readily available these days.

 

I'm gonna say welding a nut on is the only way left to get that off. the metal of the plug is just too soft for anything to actually grip it and hold

I'm personally a big fan of the HF easy flux 125 for little welding projects. I can't remember how much its going for now, but picking up the welder, some gloves, and a cheapo helmet are going to pay for itself in the time and hokie pokie saved by getting it done yourself. I've used it to weld nuts on multiple broken bolts or weld in weld-nuts to repair threads and its worth its weight in gold when it can solve your problems

 

Also pick up one of these from your Lexus dealer or on ebay. It uses the same washer as Toyota, just not a 10mm hex

 

have you cracked the fill plug. Dont drain unless you have the ability to get the fill plug out.

 

When mine was stuck, I cut a notch in the side and hit it with an air chisel. It walked right out.