Rear differential fill bolt stripped

[Squshiee]

I recently purchased a uzj100 and was changing all the fluids and completely stripped the rear diff fill bolt. I was wondering if there is a way to fill through the drain plug or will I have to get an extractor. It would be preferable to not destroy the bolt as I’m going on a long trip soon and don’t have time to wait for the new bolt to arrive

 

[GerLC100]

My first idea would be to weld on a nut or something to get the bolt out...

I guess a picture will help the more experienced users here to offer better advice.

 

[DIRTBIKEUSA]

My first idea would be to weld on a nut or something to get the bolt out...

I guess a picture will help the more experienced users here to offer better advice.

That should work.

Or if there is enough room try using a pipe wrench.

 

[GOLIGHTLY]

A bottle of mapp gas and a narrow tipped punch + hammer works miracles once all other options fail

 

[western flyer]

Since you are in a tight pinch for time due to your approaching road trip, if you cannot effectively remove the fill plug (e.g., welding on a nut to the fill plug, or the hammer/punch method, as suggested above) you can likely figure out how to fill the diff with oil through diff breather hole at the top of the housing. You may have to get a little bit creative, but a typical oil hand pump, etc. would do it. Figuring out that you have filled the diff to the correct diff oil level will be tough (since the fill plug will still be in there), though you can figure out what the oil fill volume should be and then fill it with that pre-measured amount of oil. Below is the parts diagram to show you where the diff breather is mounted. Cheers.

https://partsouq.com/en/catalog/genuine/unit?c=Toyota&ssd=$HQwdckgWXEYRDhQ9LDcQHxZcQREOFCExPHFxBAR4CgQHW1RIAwcCFx4RV1VJX1sFCgUGBwMWGkkIGhAJFn1oeQUGXilUdXB5Z2ERGBQNDB0QCQUMHhFCVUlfF0dfWEhMRl1SKx5bUVpQFwgBGBQNDB0QCRYBAwMFFEdHEFwRDhcGAgUBWlw6EE5KanJQQHcRAw4FeFt7QRI$&vid=0&cid=2&uid=335670&q=JTECB01J901011146

 

[SmoothLC]

3.5 quarts for the rear

 

[Squshiee]

Since you are in a tight pinch for time due to your approaching road trip, if you cannot effectively remove the fill plug (e.g., welding on a nut to the fill plug, or the hammer/punch method, as suggested above) you can likely figure out how to fill the diff with oil through diff breather hole at the top of the housing. You may have to get a little bit creative, but a typical oil hand pump, etc. would do it. Figuring out that you have filled the diff to the correct diff oil level will be tough (since the fill plug will still be in there), though you can figure out what the oil fill volume should be and then fill it with that pre-measured amount of oil. Below is the parts diagram to show you where the diff breather is mounted. Cheers.

https://partsouq.com/en/catalog/genuine/unit?c=Toyota&ssd=$HQwdckgWXEYRDhQ9LDcQHxZcQREOFCExPHFxBAR4CgQHW1RIAwcCFx4RV1VJX1sFCgUGBwMWGkkIGhAJFn1oeQUGXilUdXB5Z2ERGBQNDB0QCQUMHhFCVUlfF0dfWEhMRl1SKx5bUVpQFwgBGBQNDB0QCRYBAwMFFEdHEFwRDhcGAgUBWlw6EE5KanJQQHcRAw4FeFt7QRI$&vid=0&cid=2&uid=335670&q=JTECB01J901011146

Thank you very much I was able to pump it into the pressure regulator though it was a massive pain I got all 3.5 quarts in

 

[3_puppies]

not to rub salt in the wound but this is why it is a good reason to make sure the fill plug is loose before draining

 

[Squshiee]

not to rub salt in the wound but this is why it is a good reason to make sure the fill plug is loose before draining

I didn’t drain it before posting this thread. I just didn’t not have enough time to order a new bolt

 

[3_puppies]

I didn’t drain it before posting this thread. I just didn’t not have enough time to order a new bolt

when you started asking about filling thru the drain plug, it seemed as it was drained already

 

[badlander]

Normally, a whack on the head of the bolt with a hammer will loosen it because it further crushes the crush washer. This is pretty much standard procedure. Have you tried this?