I have a seized differential fill plug that the head is already pretty chewed. Any recommendations on how to remove it without breaking it off?
Recommendations on how to remove a seized differential fill plug (1 Viewer)
- Thread starter ATLTJ
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Two best options I have found are a chisel and a dremel to clean up around the plug and give it something for a socket to grab. Or if you have access to a welder, weld a new nut onto the plug and remove it that way.
This happened to me last week on the tcase, get yourself a chizel and a hammer @ the 3 o"clock position wack it and with a big screw driver wack it again. I also heated it up with a propane torch....works everytime!
Living in the Past
SILVER Star
If the nut is already messed up I would clamp a visegrip on as tight as you can and smack hard with a larger hammer. I have also drove a socket on and used a 24" cheater bar. Use a small floor jack on the of the bar. If you can get the socket to grip the nut you can get a lot of pressure on the nut. This works best of you have six point not twelve point socket.
Weld a large nut on it and use the new nut to remove it. You can also shave down the end of your socket to get a better bite on it. The heads on those things are shallow and the rounded “entrance” to the socket can cause a poor grip on the head of the bolt.
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Been a fan of the welded nut approach ever since I read about it...on this forum. 
GA Architect
SILVER Star
And while you are fiddling with getting that sucker off, if you haven't already, you may want to look at obtaining a few of these for replacements:
Allen head plugs (drain & fill on Transfer, transmission & front/rear Diffs = 8 of them) 90341-18021
Gasket (Transmission & front/rear diffs = 6 of them) 12157-10010
Gasket (Transfer case = 2 of them) 90430-A0003
Allen head plugs (drain & fill on Transfer, transmission & front/rear Diffs = 8 of them) 90341-18021
Gasket (Transmission & front/rear diffs = 6 of them) 12157-10010
Gasket (Transfer case = 2 of them) 90430-A0003
- Thread starter
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Thank you all- @GA Architect ordered!
4Cruisers
SILVER Star
A 15/16" 6-point socket is just a tad tighter on the 24mm head of the fill plug. I used that socket and my DeWalt impact driver to remove a stubborn fill plug in an O-Reilly's parking lot in Las Vegas last year when I was flat towing my '71 FJ40 back to New Mexico for its rebuild. Heard a slight rumbling sound for the first few miles and knew I had to add fluid before hitting the highway.
Rooster47
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Was glad I saw this @GA Architect and am now getting ready to order them. Just curious what's different about the Transfer Case Gaskets?
GA Architect
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Aluminum housing
GA Architect
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FWIW - The torque specs I used are as follows:
Front & Rear Differentials @ 36 ft/lbs (steel housing)
Transmission @ 27 ft/lbs (steel housing)
Transfer case @ 19 ft/lbs (aluminum housing)
When worst comes to worst:
sbman
Supporting Vendor
This is a real fail on Toyota's part, allowing their axle vendor to use these s***ty fill plugs. Reduced height heads manufactured with swiss cheese metal? Do better.
Thx for the part numbers for the hex based plugs!
Thx for the part numbers for the hex based plugs!
Oldish thread here new job for me.
Can anyone confirm the part numbers @GA Architect provided are the same crush gaskets and hex heads drain/fill plugs for a 78’ FJ55?
My part number finding skillz are not what they need to be.
Can anyone confirm the part numbers @GA Architect provided are the same crush gaskets and hex heads drain/fill plugs for a 78’ FJ55?
My part number finding skillz are not what they need to be.
So am I to understand by the thumbs up from @charliemeyer007 and @rainingagain that those part numbers will in fact work on my pigs axels and tranny/transfer case?
You have to speak slowly and use small words so I can follow
You have to speak slowly and use small words so I can follow
pb4ugo
SILVER Star
There are some vendors who offer fill and drain plugs that use an Allen wrench instead of the hex head.
I think that the diff plugs are 18mm. So same numerical prefix but will have 18 in the suffix.So am I to understand by the thumbs up from @charliemeyer007 and @rainingagain that those part numbers will in fact work on my pigs axels and tranny/transfer case?
You have to speak slowly and use small words so I can follow
Living in the Past
SILVER Star
Click on part numbers in GA Architect's post. If it wants you to join and give your information just close that window with the X in the upper right. Parts comes as a plug and two different gaskets. Not discontinued numbers so should be good to go.
