Weekend before last, I did the timing belt/H20 pump change on my 2000 4Runner. Everything went very smooth, with no problems. Took me about 4 hours total.

Well last weekend, It was time to do my Fuel Filter, Rear Diff, X-fer case, Tranny fluid, and Front diff. Again everything went super smooth...no issues....Until I got to the front diff (last thing on the list). The fill plug came out easy as pie...but the dang Drain plug is in there FOR LIFE!! I started out w/ a 3/8" socket wrench....then I hit it w/ the impact...then I tried a 1/2" breaker-bar...then I smacked the bar w/ a BFH....I did head stands and cartwheels...and that damn thing WILL NOT BUDGE!

It's been soaked in PB (even though it really isn't rusty)...still nothing. Anyone have any tips for this? Heat perhaps? My next option is to take it to the Stealership and see if they can pop it free...It just p!sse$ me off that I'm being beaten by a drain plug.

 

Same boat as you, I could not find a bit large enough to fit on my impact gun to get the drain bolt out anywhere. So I ended up removing the fill bolt and using one of those $5 gear oil pumps to suck the oil out of the front diff. Then I just filled it up with new oil.

 

I had to get a bolt welded to the front diff plug to get it out.

 

2 foot section of pipe. go to ace, plumbing section and get some steel pipe. break it loose and return the pipe! thats what i do when i get a stubborn bolt.

you said 1/2 breaker bar...not sure if thats what i described or not.

 

A floor jack handle works great as a cheater bar too.

I had some trouble with mine, but a butterfly impact gun got it out no problem.

 

just an idea, but if everything is cold then maybe thats the problem, do it right after u have driven the vehicle, things expand with heat, just an idea. my solution, breaker+steel pipe+bfg=yet to fail me

 

Try not to strip the plug hex hole tho

 

Yeah, that is a concern. The craftman 10mm hex socket is a nice snug fit...but I don't want to push my luck and strip it out.

I did put my finger in and check the color. I looks pretty decent...mostly clear/yellow still. I also tried using the hose/pump trick to siphon it out of the fill hole...but I couldn't get the hose deep enuff in to really suck anything. It felt like something was interfering (the differential I'm assuming). Perhaps I used a smaller diameter, more flexible hose, that might work. I was using pretty rigid 3/8" hose/tubing.

Well, at least I'm not alone in my troubles. I guess I'll try some heat this weekend and see if that helps.

Thanks guys.

 

I bet my IR 2135QTI would get it loose. Up to 1000 ft/lbs NBT.

 

Jiffy lube has a pump to pump it out from the fill hole if worst comes to worst

 

I was able to get a quart or more out with a hand pump. Just keep fishing the hose in there till it starts to go to the bottom. Or go get an electric impact gun and try to get the drain plug out with that hex socket you got.

 

says it all!

 

That would be more likely to snap off the tool or make a nice round hole out of the 10mm allen. Heck, I have snapped spring shackle bolts with my IR2131 (like I said, I got mine loose with just a butterfly impact....no sweat), but I don't think rediculous torque is the answer in this case anyway. A little finesse goes a long way.

 

I too had this problem, I took it over to the grease monkey, it took them about 2 hours to get that thing off, not quite sure what they ended up using but i couldn't for the life of me get it off. just my .02

 

i thought of this thread today...

i have shackles on the front of mine, so what i did was put the 10mm hex socket and ratchet in place, held on to the shackles with my hands, and pushed the ratchet with my heel and it eventually gave.

i don't suggest this method.

 

You could try to take a small ball pien hammer and lightly tap the head of the plug (straight down on it like you're trying to hammer it into the hole), this may jar it a little and let it be turned with the ratchet.

 

Well, there ya go. I suspect your best answers will come from dealer techs. But not now! Run into that problem all the time. Easy fix!

 

So, humor the rest of us and tell us this easy method so next time we run into it we can fix it. pm me, thanks.

 

Well, that last post was intended for the dealership basher. Not the rest. Several things i do to get it lose. First, take a large drift pin punch (I actually use an old kingpin from a Ford) and smack the head of the drain plug a couple of time hard. And then try it, if that doesnt do it (and it usually does), then my last option is just an air chisel with a blunt rounded tip, and drive it in the edge in a CCW fashion, this have NEVER failed me and usuaulyl doesnt even ruin the plug itself.

 

Mine is stuck too. The first 10mm allen socket that I used literally snapped in half. The second one bent/twisted and looks like a candy cane. Then the 3rd one I used in conjuction with a big breaker bar and stripped the hole. This was all done with PB blaster soaking in and everything. I don't get why they used an allen head plug up front. It pisses me off.