Stripped Front Diff Fill Plug

I was changing my F&R Diff and Xfr Case fluid last night. Rear diff and xfr case went fine. I dropped the skid plate and located the hex screws on the front fill and drain plugs. Reading the recommendation to always start with the fill plug, I inserted the T55 and immediately noticed that it had already been a bit rounded out. I did my best to be gentle, but ended up completely rounding out the plug.

I don't think I have the means to get it out myself. So, my question is:

Is it worth taking it somewhere to have this plug removed just to have the front diff fluid replaced? The truck has 200k miles and I rarely use 4x4. Worth it or Let er eat?

 

It's a 5 minute welding job to have someone weld a nut on it. Find a friend with a welder and get it done. Definitely worth the time.

Check out the pic near the bottom of the first page in this thread. @Running Man did a good job off adding a nut to his.

https://www.tacomaworld.com/threads/front-dif-drain-plug-seized.639373/

 

https://youtu.be/hFnOejt3VIU

 

Those drain plugs don't take a T55 torx, they take a 10MM hex socket. You might be able to salvage this situation on your own if you get the correct socket, dig the grease and dirt out of the drain plug with an o-ring pick or small screwdriver, and tap the socket all the way in with a hammer. Then with a small breaker bar, rap the end of it while loosening and you MIGHT get it out.

 

I did my diffs recently and i dont think the front diff had ever been changed. I could not find a metric 10mm socket so i ended up using a 3/8 and it wanted to strip so i stopped. I have the plug a few good whacks with a hammer and i tried again and it came out easy. Try smacking on it.

 

Clean as best you can 10mm hex bit

Good epoxy let cure .If you don`t weld!!

10mm six point socket remove

Install new plug I use the normal Hex plugs not the Allen type

Far cheaper then paying a shop who knows how much $50.00 plus at least

 

This tool worked easily for me.
Then replace with a new one or just weld a socket on like I did.

$23 XEWEA 13Pcs Screw Extractor Set Multi-Spline Easy Out Bolt Extractor Kit, Chrome Molybdenum Alloy Steel Hex Head Bolt Remover Tool for Broken Stripped Rusted Bolts Screws Nuts

https://www.amazon.com/dp/B09W5PW588?ref=ppx_yo2ov_dt_b_product_details&th=1

 

Better late then never !

2019 thread!

 

I notched mine with a Dremel and used a chisel/hammer to knock it loose. If seized though, probably not going to work.