If it's not one thing, it's another. Rounded diff plug.

thanks

 

Suggest you replace it with a front diff fill plug PN 90341-18066. It has a deeply recessed socket head for a 10 mm allen key. Easier to remove the next time you change the diff fluid, and a smoother surface for the trails.

 

actually i'm having the same problem with my front diff plug now. since that area gets the most of all the weather first, its all rusted. i tried removing it with my 10mm, and well now its pretty well rounded out. it sucks.

 

Another thing to try is a good sized pipe wrench. I've used this a few times after vice grips wouldn't grab it, as long as you can get the wrench on the bolt head it will grab and turn it.

 

^^^^^^ Took one off pals ford, pipe wrench was the only way and yes dealer on a new one. Jim

 

That'll work on a bolt that isn't recessed, like the diff plug.

Tapping a 6 sided 24mm onto the damaged head, after filing off the burrs, is an option.

Cornwell, Snap-on, Mac... Take your pick. They all offer Bolt extractors for 24mm. I only use welding on anything with bearings as a last resort. Ground issues have caused welded bearings in the past.
$22 for a tool, or $$$ for a repaired housing or replacement axle. Hmmm... decisions, decisions

 

i was going to change my diff oil, i got under it and its already rounded off. so i was like great. i will wait for another day lol. i like welding the wrench to the nut idea

 

Well, back from town. Not Lowe's, Home Depot, Ace, Oriely's, or AutoZone had a 24mm or a 15/16 6 point socket. . . Holy wtf. . . I found one 15/16 12 point socket, but I already have one of those. . . I bought a Makita cordless impact today, and I'm goign to try the tranfer case and front diff. I'm just going to take the rear diff somewhere to get done. I'll be picking up a new rear diff plug tomorrow from the deal, and I'm probably going to just let them do the rear diff.

 

Have you tried Sears in their Craftsman tools section? Got mine in 1/2" drive so a breaker bar goes on without adapters.

Crap ... Gonna take a look at mine the next time I'm under the truck. Maybe the TRD OR's skid plate reduces the amount of grime thrown onto the front diff.

 

yeah it sucks. it was fine the first time i changed the fluid, now....not so much.

 

I had the same problem on my older Tacoma transfer case plug. Rounded it all to hell, nothing would break it loose. i finally took the grinder to it, once everything was ground smooth, it back itself right out. I even tried to drill and use a bolt out kit, that didn't even work.

I did have another plug on hand from the dealer, I dont remember the price but it was cheaper than a new case.

 

You guys know that if you can not remove fill plug you can always refill diff through the breather, right

 

Well, the replacement plug is supposed to be here tomorrow. I went today and bought an impact/drill combo kit form Home Depot (18v Makita cordless) . I was fed up with not having the right tools, so I spent a little money today lol. I got the front diff/transfer done just now, and will try the rear diff again tomorrow when the replacement gets here. Idk what that smell is in the diff oil, but I don't want to smell it for a long time. . . mother damn.

 

^ Yeah, it's the same smell as CV grease. Synthetic diff fluid has it too.

That's good idea. May even have greater clearance for the bottle for faster filling. Just need to be precise with the volume to avoid overfilling (measuring cup or graduated cyl). I'll do it next time and do the breather extension mod at the same time.

 

Yeah, gear oil smells like serious dinosaur ass.

 

Heat and a pipe wrench ...or it ain't tight.

Mapgas is all you should need.

 

LOL yep! I lol'd!

 

The smell is sulfur. It's the additive that provides the best protection for gear drives, as long as there's no yellow metals(it attacks them).
Impact sockets are usually 6point. It fits in the recess for the rear diff, I just checked. Make sure you use a piece of wood or brass drift between the socket and hammer, or you'll deform your socket.

 

FINALLY GOT IT! WOOOOT! Brand new shiny fill plug



I finally found a 15/16 6-point socket. I beat it on the plug with a hammer anda block of wood, and attached my Makita Impact, and it didn't budge. Finally got it loose with a breaker bar. IT DIDN'T BEAT ME!

 

Awesome man!