Front diff drain plug seized up and striped, any advise?

I just did my differentials and transfer case at 10k. Toyota calls for a 15k service of in the severe catagory.

Strangely, there was more “metalic dust” in the front diff. Nearly none in the rear. Case was clean as well

 

I'm getting ready to do my diffs at 30k; got the Lexus drain and fill plugs ready to swap in. Really hoping I don't have to chisel my way out in the front. Transfer Case can wait a bit longer.

 

I will be doing this soon myself. I have the Lexus drain plug to swap in the front, didn't know they had a fill replacement also.
Good job OP, I'm curious how bad the fluid in mine will look as I'm the third owner.

 

got mine out with a 3/8 ratchet
Be sure to remove the fill before the drain

 

Hey folks, getting ready to do mine. Knocked out the rear a few weeks ago. What are the Lexus plugs? Regular bolt vs. Hex or something?

 

See the image in the quote above. It has the part number for you.

The Lexus plug uses a standard hex bolt head, instead of an Allen key.

 

Seems like a no-brainer. Is there a Lexus Hex-nut version for the fill plug too?

 

Nothing really wrong with the Allen key plug.
Just need to remove debris and use a quality 10mm

 

+1 on the Lexus parts, my fill plug was a bitch to get out and I put it in the last time. Never again.

 

Drain - 9034118060
Fill - 9034124016

Got both for $16 from Bell Lexus of Scottsdale when they had free shipping and 10% off a few weeks ago.

 

It went as terribly as one would expect. Soaked with liquid wrench for 4 days, but I don't think that did anything. Then heated it up with propane torch (maybe not long enough).

Put in a T55 torx, and tried with a breaker bar, no budge. Then upgraded to impact, started at level 1, then stepped to level 2 and 3, which stripped the T55 to a nice pretty little circle. Then tried the chisel method, but could not get enough leverage

I called the dealer and asked if they can crack it loose next week, which is my backup plan if my welder guy is busy.

 

$82 IRWIN Screw Extractor Set, Hex Head, Multi-Spline, 25-Piece (53227)

https://www.amazon.com/gp/product/B0002SRG66?ie=UTF8

I have used this kit before to get a stripped one out.

I would heat it up first.

Otherwise have a nut welded to it, and then replace it.

In the future, you have to heat it up, take a pick and clean the hole, tap the 10mm into place and use a really long 3/8" Rachet

 

I belive you need to use 6 point 10 mm hex bit

 

Aye, but that originally stripped it. It was fully seated, and high quality (10mm Hex Tekton). The bolt (I believe is aluminium) is so soft, that the hex socket (and also the T55) just further stripped it.


Dealer said they'd crack it loose for me, and I am fine with that if my welder buddy doesn't get back to me before next week.

 

So this at least goes back to 2005 2nd gen...they STILL use that dam hex plug?

 

I literally just spun my bolt this afternoon.

I'm letting the dealer deal with this one. I hate myself for saying that, but at least right now after the debacle of fluids today, I’m good with throwing money at it next spring.

 

I used heat and air impact to remove mine, had to replace it after. Used anti sneeze on the new one.

 

After I pulled out every trick in the book, I think the key was just more leverage. I explained the situation to the dealer, and shared 30+ different threads on TW in regards to this being a real issue. After the tech lifted the truck up in the air, he gave the plug a few more good whacks with a flat chisel and it started to move. I'm sure if I just kept hitting it myself (laying on the ground) it probably would have budged, but I didn't want to risk damaging threads or worse. They charged me $50, which I was fine with as they originally quoted $120. Put some anti-sieze on the new OEM plug I bought online, and next time I change I'll just use the Lexus drain and fill.

 

Before trying to remove the plug, it is a good idea to shock it. Take a punch or drift that is about the same size and give it a good whack with a hammer. This might need to be repeated once or twice but should break free the corrosion and allow for easier removal.

 

Just went through the same process, both plugs were stripped.
Thankfully not seised so an iron chisel got both of them out.

Parts used:
Toyota Fill plug: 90341-18060
Lexus Drain plug: 90341-24016