Rear diff stripped drain plug

I was doing maintenance on my Taco and when it came to changing the rear diff oïl, something weird happened. I removed the fill plug first, then tried to remove the drain plug but it won't come off.

I have a good snug fit on the nut with my 24mm socket and it's not the nut who is stripped but rather what appears to be the treads either on the drain plug itself or the diff. All it does is turn without coming out!

Anybody seen this before and know how to fix it.

 

Anybody?

 

Is it leaking? Can't quite imagine how this could be and it not be leaking.........

Can you post a pic of the diff showing the plug area? Might help with some ideas.

 

Try wedging a small flat-blade screwdriver between the differential and the head of the drain plug as you turn it. A little outward force may be enough to get it moving. There is a lot of metal around the drain plug, I am sure you can tap it and put a larger diameter plug (or a cut-off bolt) in its place.

 

Rule of thumb always loosen the file plug first.

I guess you never checked the fluid level either.

 

And you think he didn't because?

 

Another Rule of Thumb : completely read, and understand, entire original post

 

Sorry my 5th grade education shows at times!!

 

If you can't get the socket to catch, you might need to use an angle grinder to carefully flatten the edges of the plug. If you can get another socket to fit, try that. If not, you can use an adjustable wrench on it. Make sure the wrench is a good quality one that doesn't have much slop in it. Once you get the plug out, buy a replacement. Don't put it back on there.

Good luck,

 

Touche!

The flat blade screw driver method might work to remove it. OP: can you get the plug to tighten again?

 

^THIS.

 

Haha didnt mean to be a peckerhead! Couldnt resist.

 

Haha, no offence taken!

 

Paging OP. Any updates on the bolt removal?

Bringing this thread back from the dead. This is the closest topic I could find to the same issue ive created with my 2nd Gen Rear diff drain plug. The bolt just spins and spins, wont get any tighter. Thinking its also the actual drain plug threads.

I know once I get the bolt out, i'll have to tap the hole and get a larger drain plug bolt, just trying to figure out how to get this dang bolt out first.

 

Did you try the method that was suggested?

 

OP logged out 5 years ago
Try using a flat blade under plug while turning

 

Thank you, i'll try that once i've bought a second bolt.

I've been reading about tapping, and I saw a few people recommend using a thread restoration kit instead. Do you have any experience with these?

 

Not yet, I don't have a replacement bolt yet (Just in case). Trying to get an idea of all the different ways to go about this, to make sure I have all the necessary tools before I start this project.

 

Wow, just took a quick look around McMaster Carr and this seems like an expensive project unfortunately.. Roughly $170 just for an M18 drill and tap (I think the stock size is M16). I would feel better with new threads, but an M16 helicoil may work just as well. Not any cheaper though.. Also getting all of the chips out of the diff before refilling would be a consideration