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Tip for removing stubborn diff fill plug?

Discussion in '2nd Gen. Tacomas (2005-2015)' started by VTDave, May 7, 2010.

  1. May 7, 2010 at 6:25 AM
    #1
    VTDave

    VTDave [OP] Well-Known Member

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    My rear diff fill plug looks like someone beat the snot out of it with an air tool. It's on there tight and the corners are slightly rounded, but probably salvageable. Any tips for getting it off? I've already tried penetrating oil and tapping the breaker bar with a hammer.

    The problem is that the the bolt head is pretty shallow and when I tried to use a breaker bar to get enough torque on it, it seemed like the socket was going to slip off. There just wasn't enough bolt head material for the socket to hang onto.

    I thought about hitting it with heat, but perhaps MAPP gas torch + diff oil = bad idea.

    Ideas?

    Thanks
    Dave
     
  2. May 7, 2010 at 6:26 AM
    #2
    chris4x4

    chris4x4 With sufficient thrust, pigs fly just fine. Moderator

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    Keep tapping the wrench with a hammer
     
  3. May 7, 2010 at 6:35 AM
    #3
    rob1

    rob1 Well-Known Member

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    Key word, TAPPING, NOT to be confused with Banging!!:D
     
  4. May 7, 2010 at 6:37 AM
    #4
    VTDave

    VTDave [OP] Well-Known Member

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    Chris: how long would you tap w/ the hammer before switching to Plan B (to be determined)?

    I tapped it for ~ 5 minutes. Tonight I'll give it another try.

    (Ok, bring on all the sarcastic comments about TAPPING THAT!! FOR ONLY 5 MINUTES?)
     
  5. May 7, 2010 at 6:38 AM
    #5
    GSRON

    GSRON Well-Known Member

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    6 point socket and grind (or turn on a lathe) the bevel off the end of the socket. The end of the socket that goes on the Drain Plug should be square so you get max bite on the bolt.....

    There's plenty of bolt to get a bite on, just not enuf socket until the bevel is gone....
     
  6. May 7, 2010 at 6:38 AM
    #6
    chris4x4

    chris4x4 With sufficient thrust, pigs fly just fine. Moderator

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    I would try it off and on for about 10 mins.
     
  7. May 7, 2010 at 6:47 AM
    #7
    rob1

    rob1 Well-Known Member

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    Just be patient with it and it should break loose. Turning the right way??
     
  8. May 7, 2010 at 8:08 AM
    #8
    aficianado

    aficianado Well-Known Member

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    back to bone stock.
    you have a new one (fill plug) at the ready, right?
     
  9. May 7, 2010 at 8:12 AM
    #9
    kris77

    kris77 Born in the Backwoods

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    vice grips and a hammer
     
  10. May 7, 2010 at 8:13 AM
    #10
    chris4x4

    chris4x4 With sufficient thrust, pigs fly just fine. Moderator

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    I dont think you can get vice grips around the fill or drain plugs on his truck
     
  11. May 7, 2010 at 8:16 AM
    #11
    kris77

    kris77 Born in the Backwoods

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    why not? The drain plug sticks down enough. They make big enough vice grips...The fill plug, Im not too sure about..

    I just changed this fluid like 2 days ago, and i cant remember if the fill plug was sticking out enough or not...Almost positive the drain plug is though.



    My bad...I knew it was sticking down..lol...Forgot it had a case around it.
     
  12. May 7, 2010 at 8:17 AM
    #12
    BlueT

    BlueT Well-Known Member

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    I moded 1999 Taco so much it had turned to Land Cruiser
    put ATF fluid on the bolt and just give time, second make sure you have tighest fit socket you can find... 6 point would be the best.
     
  13. May 7, 2010 at 8:22 AM
    #13
    wiscdave

    wiscdave Lets Do It!

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    go tow something big and get that rear end red hot...then try tapping it with a BFH
     
  14. May 7, 2010 at 8:28 AM
    #14
    aficianado

    aficianado Well-Known Member

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    i find that if you sometimes switch from a 12 pt wrench to a 6 pt, or vice a versa..you can get more bite. hell, i have even gone to a tight standard sized socket and tapped them on. all these move have a distinct "point of no return".
     
  15. May 7, 2010 at 9:12 AM
    #15
    wiscdave

    wiscdave Lets Do It!

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    Others have just asked the Dealer to help get it lose...most do it for free.
     
  16. May 8, 2010 at 4:25 AM
    #16
    Fortech

    Fortech Well-Known Member

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    Pick up a new plug, then get someone to weld a nut or old lug nut to the plug. You should have no issues getting the plug out after this.
     
  17. May 8, 2010 at 5:14 AM
    #17
    1980

    1980 Well-Known Member

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    For a rounded-off bold that you can't get purchase on you can try using a drift punch and hammer. You will probably have to tap from several different angles but eventually the bolt should start to move. An alternative is to file a couple of new parallel flats and then use an open-ended wrench and hammer. I had to do this a lot when I worked for one farmer who seemed to think that a 24" pipe wrench was the only tool they made.
     
  18. May 8, 2010 at 2:30 PM
    #18
    2.7taco

    2.7taco Well-Known Member

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    PENETRATOR LUBE!!!! All jokes aside I was being serious. I use PB Blaster and a 3/8" ratchet with a 6 sided socket. No hammers no BS, just getting the job done.

    Worst case scenario would be to heat it slightly it and give the plug a solid wrap with a small ball-peen hammer.
     
  19. May 8, 2010 at 5:19 PM
    #19
    scottri

    scottri Well-Known Member

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    That's what I would do.
     
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