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Ohhh HOW To get this DIFF PLUG OUT! - and more
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- เผยแพร่เมื่อ 20 ส.ค. 2021
- Toyota Lc120 front diff plug stuck
How To remove the Diff plug
Fourby4diesel 
Toyota Prado
Hilux Vigo
How to remove diff plug
Stripped
Overtightened
Always a good idea to make sure you can get the fill/level plug out before draining the oil !
I had this exact problem. Stuck front differential drain plug. This method worked very well, I can recommend as well. I used plenty of WD40 to prepare the nut and then used a sharper chisel to make a notch, then banged it with a bigger blunt stone chisel 20 times on the plug. Make sure you hit the large chisel in an angle towards the threads. Just keep banging and it will open eventually. No need for a spiral screw extractor, but it might work as well. Thanks for the video, it was very helpful.
Your method worked exactly as you say on my '15 4runner. had a smaller sharp chisel to make the groove, used a grinder to take the edge off of a larger chisel. 4 or 5 strikes with a 5 lb hammer and it worked like a charm. I was worried I was one of those knuckleheads who over tightened when I did my last fluid change, but usually I'm pretty easy on the torque. Fill plug came off as expected without issue. 👍Living in Massachusetts and the amount of road salts used in the winter probably contributed to the issue. Replacement plug coming in 3 days....
Had the same with mine… I used a spiral screw extractor which worked splendidly with a wrench. Very easy actually. Spiral screw extractors are available everywhere.
What size did you use?
This really helped me out a lot on my Gx470. Youre awesome.
Right on. Boogered one up really bad, tried heat, tapping with a hammer, tapping the bit in, broke a bit off in the thing and eventually rounded it out - all no-good. The hammer and chisel did the trick! Took a bit of work but all-in-all worked like a charm. Thanks so much for sharing this - this method really saved the day! (but not the plug - mine looked way worse by the time I was done ;-) A BIG THANK YOU!
Had exact same problem with my sons front diff plug on his 95 series Prado. Damn thing wouldn't budge no matter how much you swung a spanner on it. Used this method and came out real easy. Bought a new replacement plug from local Toyota dealer $22 including new crush washer. Thanks Anthony you're a real legend!
super helpful! thank you for making this video. Your method worked great for me. Cheers from the USA
Get the Lexus plug, it has an outie hex like a bolt head. I had the same thing when doing a locking rear diff swap and had to swap the front as well for gear ratios. Spiral flute extractor ended up being the ticket to get the plug out. Also that might not have been overtightented. Theres a problem where the copper washer galvanically corrodes to the plug and housing welding them up.
Edit: Okay that one might have been overtightented but the corrosion doesn't help either. Mine took easily over 100 lbs of force to break as I couldn't even break it with a breaker bar and my full weight with the extractor. Had to use my impact. I'm sure that if it had over 100lbs of torque on it when installed it would have stripped everything out.
I been following this Channel for awhile heaps of good info I decided to change my diff oil yesterday last time it was done at a mechanic shop, as soon as I looked at the drain plug I new straight away they done it to tight ended up stripping out the exact same as the one in the video, cheers for the handy chisel tip
Bada Bing, worked for me too! I did have to add a little heat to help it move but used chisels. Thank you!!!!
Some weapon that chisel Anthony, great info as usual.
You saved my bacon! One solid whack did the trick! Wish I could say someone else stripped it in the first place, but it was definitely me lol
Good going, now give a try at the fill/level plug. Badda boom badda bing from Canada 🇨🇦
Bada Bing bada boom. I was in a jam today and you saved my butt. Worked great.
Thanks mate. I think the Koan tool is pretty awesome! I'll try to order some of their products! Take care.
What do you think of welding technique? Weld a bolt to the old diff plug and unscrew like that?
Gedore allen key socket, I like it.
Its a split boot, I keep one as a spare for track-side repairs.
You can get them from the UK or US (need to pick the right size).
Toyota used to sell them too, but they stopped years ago - not much demand.
I don’t
Even with open boot the Cv will last a long time past getting you home
Got better things to do than trackside repairs / replacement
Let me tell you something I deal with that issue very often, is a common problem, and the tool that you use provides to much flexibility in the wrench, I used to put 90 degrees Allen that fits perfect in the hall and then tap hard one time with a hammer and it lose very easy but if you miss the shoot you will damage the Allen bolt, other thing is the way you mark the bolt you must hit the bolt on the lip or edge to have more room to twist. But is a pain in the ass when that happen just be patient and everything will lose.
👍👍
Great vid as always but that big chisel is looking pretty risqué - mushroomed tool heads can be lethal.
Have you got a list of people who have died from mushroomed heads or a link to the statistics
Please
What really scares me is when something is stuck but you don’t have room to swing a hammer.
Yes, I was thinking the same, but angle the chisel down slightly just to give you clearance below the mounting bracket. The strike is at a bit of an angle but it worked for me.
Hit the same issue today on a Suzuki transfer box - every plug was overtightened, got them all out - front diff, rear diff, main box - would the transfer box one come out? Would it feck. Mashed it into a hoop with the chisel - thing didn't budge. Did all the other fluids. passed the transfer box by. Tomorrow it's getting stuff welded onto it & it's getting "Explained better" to. Out, you are coming, Pal. just not with the chisel method...
For safety, I suggest you grind the mushroom off your hand me down chisel.
I was going to comment the same thing. I still have a piece of chisel in my upper lip from an accident with a mushroomed chisel. Be safe and thank you for the great video!
Love your work Anthony 🤓. Can You please dress that BMFs head?
Jobs done! Awwwwwwsum!
Yes sorry about that another mustard job just for you 😁
I have seen these on eBay as genuine Toyota part
Before I watch it I'm guessing use a large torx bit as an easy out or just use an easy out
There's no torx bit size that really fits this really well if you've already stripped it. If you stop early maybe a t60 would work. Fully rounded out it's too big for the t60 and too small still for the t70. I found this out, ended up using a spiral flute extractor and worked like a charm although I had to get at it with my impact, breaker bar wasn't enough even with my full weight.
No dude, you need to smash that plug with a flat drift straight down first before you try the index key. Do the same with c/sunk bolts.
Thats nice, but mine's much much harder than yours.
boom shaka laka
Haha how about the fill/level plug
rubberised as you tighten it, very unlikely someone will over tighten it to the point of having trouble removing it.
👍🙌
Yes obviously wrong tool used. It's easier on vehicle when it's lifted vs working on floor which is my situation. This is probably first time owners taken it to a garage, as looks like he's used quick fixes. Unless he's got it cheap, won't be to fix it up.
No obvious overtightened