Heat (within reason) and beat.
Get a small torch to heat the area, tap the plug with a wrench or hammer, try to remove. Repeat.
Don't over heat or over beat, obviously.
Edit: Is the plug stripped or just won't turn? If it won't turn, see above. If it's stripped, you'll need to weld.
A local shop pounded a large torx bit into the wallowed-out allen hole and got it to move for me. Next step would have been welding.. I'd bet even a muffler shop would do that for you.
If you don't already have it lexus makes a part for the IS series that replaces the allen hole with a 14mm bolt head. MUCH better part.
It’s stripped. Chisel it, or a BFH on a brass hammer that is against the plug. That should break the rust from the crush washer. then slam a larger bit in.
As mentioned above, repeated heating from torch should work. And Kroil. If that fails, welding a nut is a solution, which a mechanic or muffler or body shop should be able to do.
I think I’d try an impact next. I think in this application you’re less likely to damage it with an impact. I’m in the fortunate position of having multiple impacts to choose from, so I’d work my way up, but I think a 3/8 impact might yield success. I haven’t done mine, are you sure you have exact the right bit? There are like three variations of torx and none are “10mm”. Is it a 10mm Allen?
Yeah striking the brass hammer with a regular hammer. Brass will deform and shock the plug without damaging it. I’m assuming the crush washer has rusted/fused as they are prone to do
I had this issue. In the end I bought a cheap toaster welder and learned how to weld (poorly) and eventually got a good enough weld on a coupler nut to twist it out.
Getting a shop to do it is $50 cheaper, but now I have a hobby welder to play with for other stuff.
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