stuck t-case fill plug!!! need some help...

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alteredraptor

alteredraptor

10 Year 15 Year
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May 13, 2009
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Location
southeast wisconsin
for those who know the name, no i havent done any work on my runner mainly czu of no money and its been too freakin cold out... either way i havetn been drivin it czu of bad tags... any way, the fluid in my t-case came to mind after lookin thru my haynes manual, so i went to try and get the fill plug out to check the fluid, and its stuck, and i have bad luck with stripping bolts, so i stopped tryin to get the plug out, until i get some advice from the knowledgable ppl here on mud!!! so if any one has ideas of getting it out im all ears.
 
I had this problem on my diff fill plugs, along with my tcase fill plug... My recomendation is to drive it to get everything warm and then try... I stripped out the one transmission so I ended up welding a socket on it (while it was in the trans) and it worked... It seems that some of the u.s. metric sizes arent up to the spec the japs have.
 
warm helps.
what type of plug are you talking about?

6 sided socket helps
if it is the large flat type that you are talking about then you can take the socket and grind away the cam fore (sp) on the end so that it is flat and sharp. makes the socket harder to get on the plug. but it will have almost twice the hold. make sure that when you grind it you don't grind it at an angle. put an extension on it when grinding.

if you are talking about the plug that has like a 14 mm head with a shoulder on it.
BE GENTLE, IF YOU HIT IT TO HARD TO CAN CRACK THE CASE.
Put your box end wrench on it, apply a really good amount of force and TAP the head of the plug with a hammer.

there is also the little trick of putting the box end of the wrench on the bolt head and using a larger box end wrench in the end of the open end of the first wrench to give you an extended wrench.

tapping on the wrench can help.
box end wrenches can also be ground down like the socket above.

last resorts are.
welding a socket to it. I usually use a large nut welded on the inside.

very last, using a chisel to remove it. drive it in to catch the bolt trying to spin it off.


this is very important as to why you ALWAYS TAKE OUT THE FILL PLUG, BEFORE YOU PULL THE DRAIN PLUG!!!!!!!
 
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I bet you are using a 12 point, if so like already said use a 6
alteredraptor said:
for those who know the name, no i havent done any work on my runner mainly czu of no money and its been too freakin cold out... either way i havetn been drivin it czu of bad tags... any way, the fluid in my t-case came to mind after lookin thru my haynes manual, so i went to try and get the fill plug out to check the fluid, and its stuck, and i have bad luck with stripping bolts, so i stopped tryin to get the plug out, until i get some advice from the knowledgable ppl here on mud!!! so if any one has ideas of getting it out im all ears.
Click to expand...
 
missouriman said:
if it is the large flat type that you are talking about then you can take the socket and grind away the cam fore (sp) on the end so that it is flat and sharp. makes the socket harder to get on the plug. but it will have almost twice the hold. make sure that when you grind it you don't grind it at an angle. put an extension on it when grinding.
Click to expand...

chamfer?

Hold the socket on the bolt with one hand and hit the ratchet handle with your other palm. Breakout force. Do this when it's warm.
 
i had a stuck fill plug on a diff, i used a chisel and it broke loose in no more then a few whacks of the hammer

the welding a socket or a nut on it in last resort is one of the best methods available
 
Use it on it's lowest setting and go real easy, like pull the trigger half way so it just barely knocks at 1st... Then work your way up if needed.

I don't know how to explain it but an impact is more of a concussion V.s the slow, gradual pull with all your might kind of way of breaking things loose. There is no concussion with the latter...

I've see things that a impact barely struggled to break, be REAL hard to break by hand and visa versa...


The biggest thing when using a gun IMO, is; Know thy gun.

A cheap gun has nothing to do with an expensive one. BE CAREFUL. A cheap gun is good for installing bolts b/c it won't over torque them and a good expensive gun is great for breaking bolts loose.

Cross them up and you won't get bolts broke and you'll be damaging stuff b/c you have too much gun.

You need to know you can turn them up and down.
 
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well i got it off with an impact and a 15/16 i beleive, went nice and easy, came out all easy like and it was full, something i did not know, but im glad it is, this was the first time i checked it since i bought the truck 3 years ago
 
Mike C said:
They are all the same size, the diffs use steel washer gaskets, while the tcase and tranny use aluminum.
Click to expand...

I thought they were. I changed all 4 of mine but it has been a while.
 
Those plugs are a Toyota OEM part. You can get them much cheaper from the dealer, or CDan. They are used for auto tranny pan drain plugs on almost all of their cars. Both my car and Highlander have them.
 
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