Diff filler bolt/plug removal (rounded corners)

[williamhamilton]

Howdy.. I want to refill my diff but pain is that the corners on the bolt are a bit rounded and I do not want to abuse more than it has already been and getting all the blame for f^&king it up

What is best way to get it out and are replacements readily available? - FJ40 full floater.

At this stage I was considering taking diff head off and having the centre drilled out.. seems extreme but I am not a mechanic or engineer

tia

W

[chrome]

if your considering getting it drilled out you may as well have a go youself first crc and some good taps with a small hammer might loosen it up some then vice grips it out, then go buy another bolt.worth a shot

[chevrolux]

i used an angle grinder to make the sides flat to fit a crescent

[chrome]

yea id do the same , it didnt look like he had much tools. everyones got vices and a hammer usually

[nstacey]

6 sided socket... makes all the difference

[smurf182]

Definately try a 6 point socket and if that fails maybe a cold chisel and hammer.

[muddyplumber]

i rounded mine off aswell, tried vice grips etc ended up welding a rod onto the bung.worked a treat then replaced the bung

[williamhamilton]

Thanks for the feedback guys. As yet I have not totally naffed the plug but have used spanner and socket (CRC and hammer of course ) to no avail - just does not budge.

My main priority was not to round them more than already - but I think I will just have to give it a bigger bash and if I round them then deal with that in whatever way is best. Vice grips then welding it seems. Roll on Thursday so I can get back under the diff!

cheers

W

[gimmemud]

I've got an awesome crescent socket set. It grips the middle of the bolt instead of the corners. Got a couple of bolts on my truck that are a bit rounded and that set works every time. You should be able to buy single sockets from an engineering place.

[chrome]

yeah i gotta spanner set that picks up the flats too. its called metrinch used it on heaps of rounded nuts when i ownwd poxy old cars escorts and corrolas and shit

[GotFlex]

I would weld an old nut on top of the stripped pluf and then use the new nut to crack it of, then pop down to toyota and get new one

[sambo]

when one of my manifold bolts rounded i just got a size smaller (or maybe it was an imperial) socket and just bashed it on with a hammer

[albundy]

Will Nissan plugs fit in to toyotas??? I only ask as nissan bungs have a square hole that fits a socket holder perfectly and nissan bungs don't suffer this problem because of their design.
AL

[williamhamilton]

Thanks for this guys, not getting any time with the toy at the moment but hope to get another bash at this within the next couple of weeks. bought a new bit of bling which I will add to my build thread once I pick it up next week

Welding nut and (possibly) adding Nissan part sound like a good idea based n the design features (I will just have to be prepared to take the stick from the Toyota lads for having Nissan bits on it)

cheers

W