How to Remove a Stripped Differential Plug | Diff Drain Plug

In this video Terry from Jafffa Adventures removes a stripped differential drain plug (diff plug) from his 200 Series Toyota Landcruiser. You will find how to remove the plug when the alan head is stripped on the plug itself.
There are lots more "how to" videos in the LC200 playlist, check them out.
#jafffa #differential #strippedbolt

[@StephenCastelino]

Those front plugs are notoriously hard to get off. I've had to use a chisel for my last 2. This solution is the absolute best thing to do, like the Kaon plug mentioned already. Thanks Terry and great job as always.

[@JafffaAdventures]

Cheers Stephen I appreciate the kind words. I reckon you could do them up finger tight and service I’d be in the same predicament, crazy. Thanks for watching mate👍😎

[@thirdtimeround-chromenomads]

😅😅 went through exactly the same dilemma. I welded the nut on the inside to start with. Another excellent video, mate 👌

[@JafffaAdventures]

Good stuff mate, thanks for sharing👍😎

[@MudducksTouringAustralia]

Nice work Terry, good solution. Cheers Steve

[@JafffaAdventures]

Thanks Steve, we really should not even have to do this if Toyota sorted their game. Cheers👍😎

[@zoezoe610]

In stripped hex bolts you can put two similar sized allen keys in it and they lock together and you can turn the bolt. Maybe for next time someone is stuck it could help them.

[@JafffaAdventures]

Good stuff mate, thanks for sharing👍😎

[@rushthezeppelin]

Fluted extractor worked great for me. Replaced it with a Lexus plug that's not an Allen.

[@JafffaAdventures]

That’s the go mate, thanks for sharing 👍😎

[@diffened]

When you reinsert the plug, use some anti-seize or plumber's teflon tape, it actually works great at preventing the plug getting stuck and is easy and cheap.

[@JafffaAdventures]

Good tip mate, cheers

[@LockyourHubs4WDing]

Did the welding kill the magnet?

[@JafffaAdventures]

Not at all mate, still pulls like a…”fill in the blank”👍😎

[@LockyourHubs4WDing]

@@JafffaAdventures 🤣🤣🤣

[@OPTIMUS6LTR]

Kaon do a replace plug with normal 24mm hex head and magnet built in

[@JafffaAdventures]

That’s good to know, cheers👍😎

[@rashidtayidi8370]

A normal hex head plug may not be able to handle the high pressure in a differential and leak, that is why they don't make it with a regular hex drain bolt and not sure if it would not weld itself to the case (dissimilar metals)

[@JafffaAdventures]

@rashidtayidi8370 there is no pressure in a diff. If there was, the seals would blow out at the ends of the diff long before any plug leaked. Cheers

[@rashidtayidi8370]

@@JafffaAdventures Thank you for your nice video and reply. That was something I read a long time ago but it may have been very high temp combined with vibration in a differential causing leaks, that is why they design it with same metal so as not to weld together. Also in a Subaru guidance, I believe there was a mention of using a very light coating of Three Bond Gasket Maker TB1217H (silicone) on the treads to prevent leak, but also suspect making it easier for the next removal.

[@JafffaAdventures]

Cheers

[@paulmartin7737]

Would it have been possible to drill a hole and ezy-out it? Seems a bit tricky when you can only get weld on half the nut. Also, did you use any anti-seize when re-installing it?

[@JafffaAdventures]

It may have been possible, but I used the tools I had on hand and did not have an easy out large enough for the job. The difficulty I can see with an easy out is the depth of the hole you have to drill, remembering that there is a magnet on the back side of the drain plug. I’m not sure you would get enough purchase on an easy out. If you did manage to drill all the way through the plug thereby ensuring enough purchase, then you have to contend with metal shavings inadvertently getting into the diff oil and diff oil leaking out the newly formed hole. For these reasons, even if I had an easy out of the appropriate size, I would have still gone down my route. I lube the plug threads with diff oil, but anti seize is great as well. Cheers👍😎

[@paulmartin7737]

Thanks Terry, the hole would have to be deep because ezeouts are tapered, plus I forgot about the magnet.@@JafffaAdventures

[@JafffaAdventures]

Cheers👍😎

[@rushthezeppelin]

You don't even have to drill a hole since there already one there. Fluted extractor worked a treat for me when I had to do this.

[@JafffaAdventures]

@rushthezeppelin correct

[@willleslie2745]

Happened to my 2008 kluger

[@JafffaAdventures]

Copy mate😎

[@ed-cookie-Cook]

I have that problem at the moment with a FIAT Rapido camper. It is doing my head in.

[@JafffaAdventures]

Yes, it’s pretty ordinary 👍

[@RandyNoakes-u4c]

hello, what kind/brand of welder do you use? thanks

[@JafffaAdventures]

My old one was a Migomag, my new one is a Unimig. Does not really matter as long as you have something of quality that can deliver good penetration 😎👍

[@RandyNoakes-u4c]

@ thank you!

[@JafffaAdventures]

@RandyNoakes-u4c all good mate😎👍

[@orboakin8074]

Is there a method for those of us who have no welding tools or can't afford a weld?

[@JafffaAdventures]

Try a bit of heat on the diff housing (to expand it) and try and jam something into the Allen head. Failing that, drill out the centre and use an easy out. Cheers

[@kwacz]

I had this plug out of my truck twice now. It came out pretty easy. This time however, it was sized in. I hammered on it for almost 4 minutes with my impact and it wouldn't move. Next, it stripped out. Im hoping by welding an allen socket inside the thing I can get it out. Im hoping the heat breaks it free. For now though i just sucked out the fluid from the fill port. As i measured the oil going back in it appears I got about 90% of the old oil out.

[@JafffaAdventures]

Good stuff mate. It amazes me how that plug can seemingly self tighten 👍

[@kwacz]

@@JafffaAdventures i think its rusted in from road salt. Im sure when I weld the allen socket into it the heat will loosen it up.

[@JafffaAdventures]

Indeed mate

[@paulhardie9450]

Ya Nuts Terry lol 😝

[@JafffaAdventures]

Oh groan😂😎

[@ashuua2909]

THANK YOU THANK YOU THANK YOU!❤❤

[@JafffaAdventures]

All good mate👍😎

[@ashuua2909]

@JafffaAdventures Hey. So I took it to a young welder who tried to weld a steel nut to each Allen head. He tried for 3 hours and each time the weld broke very easily unfortunately. I have a lexus gs350 2007 and I think differential is cast iron. He was using a mig welder. What can be done in my case

[@JafffaAdventures]

@@ashuua2909 does not matter if the diff is cast or alloy, it’s the plug composition that matters. All the plugs are steel, so welding them is no problem. I don’t know why he could not do it, perhaps he was not getting the necessary penetration and needed to turn up the amperage. Perhaps the nut he was welding on was too small. Without being there, I cannot be certain. I’d take it to someone with experience. Good luck👍

[@ashuua2909]

@JafffaAdventures Ah, ok. I showed him your video at the beginning haha. He did not have a lift, so we had the car on Jack stands, and he must've attempted the weld at least 10 times. In the end, he said it would require "nickel"? stick welding since it is a cast iron differential.

[@ashuua2909]

But I will try a shop. They should no what to do. Can you tell me what to expect in terms of cost?

[@FirstLightAdv]

Had to do the same on my friend's 150 prado. It's just a way for Toyota engineers to upskill the diyers 😄

[@JafffaAdventures]

lol, good one🤣👍

[@chrisryan8863]

so many cars are moving towards those dumb hex drain plugs. in my honda the ATF plugs are all hex plugs and I stripped the one that you check the fluid level just today (yes, there is no dipstick to check the atf, but rather a dopy hex drain plug).

[@JafffaAdventures]

Indeed, it’s nuts👍

[@waymanrosshurley3141]

3:30 eukered??? What does that mean????

[@JafffaAdventures]

I made it up, but the derivation is from a card game called euchre. It basically means, screwed, worked over, shafted, bit me on the backside….you get the idea😉😎

[@nathanandre9717]

I'm pretty sure the Allen bolt is to discourage quick change oil techs from draining the wrong oil and blowing the engine and transmission in one go. Just a guess, though. My RAV4 has 10mm allen bolts on the ATF, transfer case, and rear differential. The oil drain is a much more common bolt. The bolt head rust is definitely a job hazard, but I wouldn't fault Toyota for this one. If every drain plug was the same, underpaid techs would destroy major systems on a daily basis if they're not trained for each and every make.

[@JafffaAdventures]

I believe you can't engineer out idiots. If someone is going to do the wrong thing, they will find a way, LOL. Cheers

[@nicknick7052]

4:08

[@JafffaAdventures]

No explosions this time 😉

[@rockbiterhd]

And why do still have my 100 series enjoy

[@JafffaAdventures]

Cheers😎

[@claytonthiedecke469]

it looks like they half copied off European cars, except European diff/gearbox plugs have an o ring seal on the face so this only requires low torque to seal. did your welding warp the sealing face? you may not have parallel faces to seal properly

[@JafffaAdventures]

No chance mate. As stated in the video I kept mating surface temperatures down to the point where it was always cool to the touch. Thousands of km’s on it since the “fix”, no leaks. Enjoy your journey mate👍😎

[@iandibley8032]

G'day Terry sure is dumb arse engineering, I had this problem on Hilux 2003 I had years ago, Toyota Corolla sump plug has the same pitch thread and a male hex .The guy in spare parts said plenty sold for this fix.

[@JafffaAdventures]

Thanks for sharing Ian. It is heartening to know that I am not the only one falling victim to engineering stupidity👍😎

[@rebeccabins]

😕 promo sm

[@JafffaAdventures]

What’s a promo sm?