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Front diff filler plug stripped

PostPosted: Wed, 29 Dec 2010 2:35 +0000
by Bourbydol
Bit of Quick adviced/help/suggestions needed!!!

I am in the middle of changing all my oils in the lux & can't get the front diff filler plug out! :evil: Have been at it with WD40, a long socket extension & hammer to give it a jolt but it's in such an shiitie position can't realy get any leverage with my allen keys......

Any suggestions????!!!!

diff help

PostPosted: Tue, 11 Nov 2014 6:43 +0000
by dossy92
Iv stripped the filler bolt on the front diff.

its in the workshop now to have it removed. They need me to get them a replacement plug but no one lists what size bolt/thread it is. Toyota said 3 day wait. Im running around sydney looking but with out the old one no one can help unless i have a size

Re: diff help

PostPosted: Tue, 11 Nov 2014 8:09 +0000
by packeteer
maybe try wreckers

http://4x4partsnsw-px.rtrk.com.au/ <- Sydney
http://www.justhilux.com.au/ <- Vic

part number:
41110P PLUG, FRONT DIFFERENTIAL DRAIN
90341-T0003

Re: diff help

PostPosted: Tue, 11 Nov 2014 8:23 +0000
by packeteer
been trying to find my workshop manual (pdf), but I seem to have lost it

Re: diff help

PostPosted: Tue, 11 Nov 2014 8:52 +0000
by dossy92
Most pf them want to sell me the whole diff and can not tell me a plug size. Iv got my hands on some 18mm x 1.5mm and some 20m x 1.5mm and i just hole like hell one fits.

i couldnt find anything in the gregorys manul

Re: diff help

PostPosted: Tue, 11 Nov 2014 8:54 +0000
by packeteer
might time for a test drive? ;)

Re: diff help

PostPosted: Tue, 11 Nov 2014 9:11 +0000
by dossy92
Test drive into a work shop fpr an inspection and notofy them the plug is missing...yer its crossed my mind haha

Re: diff help

PostPosted: Tue, 11 Nov 2014 11:12 +0000
by dossy92
Hilux Front diff Filler plug size. 18mm x 1.5mm
Hilux front diff drain plug size 24mm x 1.5mm

if anyone else has any issues here it all is for you

said how it is so any one who googles it can find it.

Re: diff help

PostPosted: Fri, 02 Jan 2015 9:06 +0000
by 1tuff4b
What's the trick to removing the filler plug on the front diff?? Mine is an Allen key type plug along with the drain plug and you just can't get in there. Have done the rear diff, tranny & box and they have the 24mm bolt [emoji35]

Re: diff help

PostPosted: Fri, 02 Jan 2015 9:39 +0000
by fnqtech
Trick is an Allen key socket and long extension. I got an impact socket from Supercheap.

Re: diff help

PostPosted: Fri, 02 Jan 2015 1:33 +0000
by 1tuff4b
Have given up ATM. Tried the Allen key socket, managed to crack the filler open but my biggest problem is the drain plug. Tried an extension on the end of my ratchet, air gun, even had the full force of my leg pushing the bloody thing to try and loosen it. Ended up busting my king chrome ratchet & stripped the hex plug. So for the time being the old oil can stay in. Rear diff & transfer where clean, gearbox was dirty. Hopefully the front diff oil is clean!!

Re: diff help

PostPosted: Fri, 02 Jan 2015 3:52 +0000
by dossy92
If the nut is stripped either
1 weld a socket on and use a breaker bar

or

2 get a inverted torx socket ( normal socket but with torx type head) hammer it on and use a breaker bar. You will need a new plug (25mm with 1.5mm thread).

3 drill a smallish hole in the plug but not all the way through and hammer a nornal torx head socket in


if you get a socket on it use a breaker bar. Point the handle to the back of the car and then lower the car gently on to it.

Re: diff help

PostPosted: Fri, 02 Jan 2015 7:05 +0000
by 1tuff4b
Cheers for the reply dossy92
I'll weld a socket on and see how I go with that technique
Is this a common fault? Can the plugs be replaced with the same type as the rear diff & boxes?

Re: diff help

PostPosted: Fri, 02 Jan 2015 9:54 +0000
by dossy92
If you mean a hex head then yes i ran around looking for sizings and stuff and finaly got some. I got an extra pof each just incase aswell.

just becareful of heating the diff to much as you can crack it if you heat it to much.

Re: HELP -Trouble with front diff filler plug

PostPosted: Thu, 21 Jan 2016 5:06 +0000
by fourby4diesel
Sorry for late reply ;) :D

we do regularly see problems with removing the front diff drain plugs.
Either they have been over tightened, and/or been previously butchered.
Image
Image
You see sometimes they can't put the tool in all the way, no good.
Usually i use a good 10mm hex head socket, add a chisel if needed.

Today I thought I would try Roos nuts, it's a special tool from http://www.tnnengineering.com/.
It worked really well.
It basically converts a10mm hex to a 24mm socket.
Because of the flat surface it helps keep the tool square.

FRONT DIFF DRAIN PLUG

Image
Image
Image
Image
Image
Image

So I put a new plug, I prefer to start fresh as I'm looking after this vehicle now.
The tool was nice n tight, just the way you like it.

I'd say a good investment for d.i.y & technicians alike.

Re: diff help

PostPosted: Thu, 28 Jan 2016 4:46 +0000
by fourby4diesel
Special tool available now.
Works great.

http://www.ebay.ph/itm/TOYOTA-HILUX-PRA ... SwGotWqK~C

Re: HELP -Trouble with front diff filler plug

PostPosted: Thu, 28 Jan 2016 4:47 +0000
by fourby4diesel

Re: diff help

PostPosted: Thu, 28 Jan 2016 5:39 +0000
by 07luxyTD
When you weld it, you will be surprised how loose the plug should have become. I normally heat just the plug with an oxy untill just starting to go cherry red then put an allen key or socket depending on the plug

Re: HELP -Trouble with front diff filler plug

PostPosted: Fri, 29 Jan 2016 6:26 +0000
by fourby4diesel
Or just put a 24mm plug in

http://www.ebay.ph/itm/Toyota-Hilux-KUN ... Sw--1WqKhs

Top quality Aussie made.

Re: HELP -Trouble with front diff filler plug

PostPosted: Fri, 29 Jan 2016 11:24 +0000
by woza_black
Whilst on the topic of drain plugs, has anyone used this kit from Drivetech?

http://www.ebay.com.au/itm/Toyota-Hilux ... SwvUlWp8Nq

Seems like a good option.