Front Differential Drain Bolt Stripped

Stripped my front diff drain plug today. Have to use a cold chisel and a hammer to removed it. I sprayed it with pb blaster and applied some heat and still won’t budge. I installed a new OEM drain bolt and tighten just enough so it won’t leak any gear oil.
The refill drain bolt came out easy. Have to used a new washer on both drain plugs.

 

weld a nut to it and zip it off with an impact, you'll never have one stick again after that.

 

Those stupid hex plugs were such a dumb idea on Toyota's part, I thought they'd realize that after the 1st gens but I guess not.

I've stripped mine on my 04 too, I used a dremel with a small cutting wheel to notch the plug and then used a chisel to tap it counter clockwise which worked really well.

Always be sure to clean out the hex plug before you try loosening it...they get filled with dirt and road grime and strip easily if not cleaned out first.

 

Man,

I just Drained my Rear, center, and was about to do the front and I tried everything to get that front Diff bolt off and I could just feel it wanting to strip... I am going to take it to the dealership and let them strip it.. Hopefully next time I can get it out on my own. I soaked it in PB blaster and let it sit overnight, breaker bars, everything! Stupid design!

 

Try using a cold chisel and a hammer first before you bring in to the dealership. I did call my local Toyota dealership and said they used the same technique to removed a stripped front diff drain bolt.

 

The trick is to use a quality 10mm hex socket and really clean out the hex hole so the socket can be properly inserted. I was expecting a ton of trouble with mine, so I purchased a Snap-On 10mm hex socket and cleaned every spec of dirt out of the hole, letting it soak with PB Blaster for a few days. It was tight as heck but it came out cleanly with no stripping. I was relieved! Those drain bolts are WAY over-torqued at the factory.

 

This. If you pair the hex socket with a quality 1/2 in 2 foot breaker bar, they come off easy. People who try to use a basic 1/2 in socket wrench usually end up stripping these bolts.

 

I agree

 

May need to take dremel with a cutting wheel to cut a small notch in it. Then use the chisel and hammer so it has something to bite onto. This worked for me.

 

Instead of cleaning the hex, I hammered the socket in. The dirt/rust actually holds the bit in the hex good and tight. Just be sure the bit is fully in. The only downside is getting the plug off the bit.

 

Just whacking the drain plug with a hammer sometimes does the trick to unstuck em.

 

Heat coupled with vibration is what makes these come off easily. You can take an over sized bit, file it to fit the stripped slot, then heat up the head of the screw. Use a breaker bar on your modified bit, and apply pressure while a helper simultaneously taps the back of your breaker bar's knuckle with a small hammer. The heat coupled with the impact of the little hammer should make it loosen easily.IIt has worked every time.

God luck.

 

Lexus drain plug.

https://www.tacomaworld.com/threads/front-diff-drain-plug-alternate-oem-part.604989/

 

This ^

 

Some variation of a hammer impact works good. Hammering on the end keeps the bit tight in place.

TEKTON 3/8" Drive Impact Screwdriver Set (7-Piece) | 2905

https://www.amazon.com/TEKTON-2905-...ocphy=9032309&hvtargid=pla-420785539586&psc=1

 

If you repair it once like it should have came from the factory, you just use a 3/4" impact socket and it will come off every time.