Front diff drain plug stuck

Quickest way I've seen this done is with an air hammer and chisel.

 

I had a drain plug like that seized up on a case international transmission. I relieved the tension by carefully using a hole saw until it was almost through and it came right out. I would have welded a nut if I had thought of it.

 

OP said they used a torch to warm it up. If you have an oxy acy set up, or a propane air set up you can braze a nut on yourself (no welder necessary). MAPP you can occasionally do low alloy silver braze but tbh it’s super finicky and doesn’t work well. You would need flux for silver, but not for bronze / brass.

just a bit of brass rod and some practice scraps will tell you right off if you can get the hang of it …

 

Find an exhaust shop, they’ll weld a nut on there.

 

Whelp, this was a good idea, but didn't budge it at all. I let the epoxy set for a full 24 hours just to be safe too. Thanks for the suggestion, but I'll be calling muffler shops this week I guess.

 

If you want to do the welding the nut trick. Go to a muffler shop(Make sure they are playing Mexican music) and tell them what you need them to do. If not an option heat the plug up and hammer a torx that it’s kinda close but a little bigger than the hexagon and go lefty loosie. Cheers!

 

Banda specifically

 

Or, for the number of times you change the diff fluid (like once per 100k mi....) just suck the oil out with an extractor and leave stripped plug in place. I use this extractor to suck oil out of jet ski and it works great. You have the fill hole open so extract, then fill....

 

Curious about the outcome, if any.

 

lol

 

None, so far. I've had the truck in the shop for some unrelated issues, haven't gotten around to this yet. I'm tempted to try brazing a nut on like someone here mentioned, but i know a solder joint likely won't withstand the torque

 

Your post made me think it's about to do mine . Of course mine was seized /rounded as well.

I went and gave these a whirl I couldn't believe how well they worked, I cleaned out the gunk the hex hole, didn't bother drilling it round, just smashed one in with a hammer. Heated a tiny area, it took me bumping my impact up some psi to get it out.

pretty impressive tool, I give it a 10

don't mind the gnarled threads, I was trying to get the extractor out! Grab on with a pair of vice grips or bench vise and turn the extractor clock wise

 

Sweet!

Im gonna go out and buy a set before tackling this project.

 

might it be good practice to remove this plug on a yearly routine basis to limit potential seizure?

 

once it’s out, replace it with the Lexus drain plug.

 

Not necessary.