rear differential drain plug leaking after fluid change

My rear differential drain plug keeps leaking after 2 attempts to fix. drain and filled diff used new oem crush washers flat side to the bolt torqued to 36 ft-lbs still get a drip from bolt maybe one drip every 8 hrs or so nothing major but annoying. It should seal 100% . Any suggestions ?

 

Are you sure there is no grit on the plug or around the hole? My dealer did some warranty work on my diff and I discovered no crush washer when I changed the fluid. I am surprised my diff was not leaking.

 

yes I cleaned both surfaces with brake cleaner. Did not see or feel any grit

 

I would try a new crush washer and put the flat side toward the Diff.

 

Let it drain overnight. Clean the surface like you did and use a "small" amount of pipe dope. I've had some trouble Toyota drain plug leaks like you describe. That has worked well, and no problem the next time you need to remove it. Don't worry about the crush washer - just re-use it, and install as described.

 

I would use thread seal.And a new crush washer. I did have this problem because The Allen stripped out and I welded a nut to it to break it loose. It leaked after that so I used this thread sealant and it worked. But I eventually replaced the plug with a new one from Toyota. Mine was the front differential though.

 

Are you really running your Diffs that hot ??

 

Quick update my differential drain plug was not leaking after all. Believe it or not it was the differential housing itself. Specially the weld around the bung for the drain plug was defective. dealer replaced entire differential housing under warrantee. been dry ever since. Probably not a common issue but it happened.