Rear Diff Fill Plug - Welded on?!? Help!

Hey guys,

I've hit the wall, after two days of trying. I feel like the diff fill plug is welded on there! I've tried the following:

24mm 6 point socket
Vise grips
Pipe wrench
All with PB Blaster

Attached are some pics of its current state.

Any help/suggestions would be great!

Thank you!!!

 

At this point you could weld a nut to the damaged nut in order to try to have a way to remove it.

 

Another picture

 

Hey your socket may have slipped a bit. Looks a little stripped.

 

Pretty sure the vise grips and pipe wrench had some part in that.

I think at this point welding a nut on would be the solution, along with a long breaker bar.

 

If you REALLY can't get it:

Disconnect your driveshaft, brake lines, U bolts, ABS cable.
Roll your axle upside down. Use the drain bolt to drain/fill.

Idk that's what came to mind if shit hits the fan.

 

chisel and hammer, air gun/chisel, or weld on it

or... grind the edges flat till you can get at it with something but I'd give the chisel a go first

 

Weld another bolt on there, it will come right out. I've done battle with a couple of bolts like that and the heat of welding breaks everything loose.

 

Ah,,salt roads..

 

There are extraction sockets that will get it. Pipe wrench is a good idea too. There must he a way, sir.

Though it's a poor idea to heat it, you could try heating it a little with a torch and breaking it loose. Makes a world of difference.

 

Weld a nut it works better then a bolt that way you can weld in the center and around the edge.

 

if it was still in good shape. I know this isnt any help now but you can take a torch to the plug heat it up a bit dont let it get red just hot and crank down on that sob and itll come right off.

 

That heat will help loosen it off as well!

 

oh and after you get it off get a new plug.

 

Man I love TW! Great suggestions

Couple questions, if I were to weld another nut/bolt on, is this something that one can do themselves, or will a visit to a shop be inevitable?

The chisel method sounds interesting (and free) but what's involved?

Anyone heard of filling through the breather? Probably not the best, but viable?

And yes, I've ordered all new plugs for the front diff, TC and rear diff. Just sucks because the rear is the one I want to do most!

Thanks again for the quick help!

 

I wouldnt chisel it off then you still have the stem of the bolt to deal with with. if you have a welder then thats a good route. I would file the edges flat (give you something more to bite too) and use vise grips since i dont have a welder.

 

No...

 

Yes. The breather unscrews pretty easily.

You can do the diff breather relocate mod while you are at it.
http://www.tacomaworld.com/forum/2nd-gen-tacomas/15686-diff-breather-mod-dummies-pics.html

 

I've done the breather mod (thanks to TW) and I may resort to filling through the breather, read it somewhere (during searches) but wasn't sure if it was acceptable.

 

chisel is very similar to bolt extractor, you tap a sharp chisel into the edge of the bolt, as perpendicular as you can get it and then tap the bolt around until you break it free and spin it out.