Stripped front diff drain plug

Hey guys need some suggestions on how to remove a stripped front diff drain plug. Guy who worked on it before me stripped it. Need so help.

Thanks

 

There are a couple different ways to go about removing it, depending on how bad it is. I assume you mean the hex key is stripped (rounded out) in the plug, and not that the threads of the plug itself are stripped. First off, soak it in PB Blaster overnight - apply some, tap it with a hammer, repeat several times. The vibrations from the hammer taps will drive the lubricant down (up) the threads.

If you have access to a welder, the easiest way is to tack weld a nut or another socket to the plug, then break it free using that. A cold chisel can also be used to cut a notch into the side of the plug, in the direction you want it to rotate (counterclockwise). Use the chisel, or a screwdriver you don't care about, and hammer it into the notch, forcing the plug to rotate. Lastly, if nothing else works, you can drill out the plug and use a screw extractor to remove it (probably want to pump the gear oil out through the fill plug first.)

Good luck, those plugs can be a bitch.

 

I had one that was stripped on my last truck. I used a combo of things all at once. Here's what I did:

Soak it with PB blaster a bunch for a few hours.

Wipe down and heat up the diff around the plug with a butane torch for about 10 minutes.

Take a hammer and bang on the plug to break loose any seized parts in the threads.

Repeat step 2 and 3.

Use a ratchet with a cheater bar and get it out.

It eventually came. If it would have stripped completely, I would have welded a nut on it like the poster above said. But you have to be careful doing that. A few months ago a poster on here tried that and ended up welding the plug closed.

There are lots of posts about this. Its a common problem on these trucks. Stupidly designed plug that is usually over-torqued at the factory.

 

I had this same issue and got a huge extractor from oreillys auto parts.

 

did you use a cheater bar or did you use a drill?

 

I used a cheater bar on a hand wrench if i am not mistaken.

 

were you able to remove the stripped drain plug?

 

Unfortunately I have not had time to get after it. I plan on trying to get it this weekend, ill keep you posted.

 

ok

 

I had Jiffy lube guys do this to my front diff fill plug. I took it back to them about a month later and pointed it out. They paid to have my truck taken elsewhere to have the plug removed but i had to purchase a new plug. They chisled it out (hammered a chisel into the plug in the direction it spins to loosen). I was in/out from there in about 10 mins. Maybe you can take it back if you were the owner at the time it was worked on?

Also... this is why i now do all the maintenance on my truck myself.

 

well, it has been terrible so far... first ended UP drilling to far and drilled all the way through the plug. Then I attempted to use the extractor and the extractor sheared off, and is recessed IN the plug. So I am trying to line up a friend who has a welder and evaluating using a hammer and chisel. I will keep posting as updates come it. WORST OIL CHANGE EVER

 

ouch that is no good.

 

So I've tried the chisel and that has not worked very well, need some new ideas. Right now I'm trying to set up a welder to come help me out.

 

All I did was hit it with a hammer...then I unscrewed it with my fingers hah

 

ya no such luck who ever did this really F***ed me

 

ugh...I have a seized fill plug on my 4runner rear diff...this thread is not giving me confidence to do mine.

 

man up take your nuts out the glass jar break it open.

 

I wish you the best of luck my friend, I am so annoyed I am having a beer to drown my sorrows right now.

 

there is nothing to grab.

 

oh, you mean kinda like you did when I was at your house and you tried to break it loose and couldn't?