Cross threaded differential fill plug!

I over tighten the differential fill bolt and cross threaded it so now it just spins. How should I go about taking it off? And how should I put a new bolt in there?

 

It won't unscrew?

 

Flat head screwdriver under the bolt head. Keep pressure against it and slowly back it out with wrench. Two ways to fix it, helicoil or drill and tap to next bolt size up.

 

Hopefully it's just the plug that stripped. If so you should be able to get one at the auto parts store. If the housing is stripped you can try chasing the threads with the appropriate tap.

 

Nope just keeps spinning

 

I read that in Dory's voice from Finding Nemo... I'm an adult.

 

I'll try that screw driver method thanks!

 

Hahaha

 

The threads are m18x1.5mm. Just keep pressure on it while prying and turn out slowly. Like I said hopefully it's just the plug that stripped.

 

Ok thanks

 

Like this: Start @ 1:22

 

you didnt cross thread it you stripped that bitch out.

They make torque wrenches n torque specs for a reason!

 

This, but if it comes out and you decide to chase the threads with a tap, put a bit of thick grease on the tap and go slow, grease will catch most of what you clean out of the threads.

 

If you stripped the housing move up to the next size tap or just cut a new hole and weld in a large inspection port. And by saying you do it I mean have a qualified person do it, how one strips it out in the first place is beyond me.

 

So I did this same thing in mine while doing the rear differential. Yes, I have a torque wrench and the proper torque settings. Sadly, despite my better judgment i trusted the torque wrench over my own intuition, which turned out to be a mistake because my torque wrench was broken...

To fix it I took your advise and I hammered a flat head into the crush washer so I could get some torque on the screw outwards and used my socket wrench to unscrew it. Sadly, the threads in both the bolt and the housing were stripped but the housing seemed recoverable so I bought a new plug and wrenched it in basically retapping the housing with a new plug. I was able to torque it to proper setting (with my brand new torque wrench and new crush washer) so i guess i will see where I am at my next differential change and if need be I will just retap the housing to 25mm or a english equiv. ughh 2 nights of work just because i bought my torque wrench at a pawn shop ....

 

Might I ask where you got your new plug? I just ran in to this problem.

 

Just go to the parts dept at the toyota dealership, the new plugs are like 11$ or something like that

 

I did this once too, took it to a mechanic he re tapped and a next bigger sized plug all is well now, if its stripped and spins it will leak gear oil.

 

I got the plug from the dealer for $10 and ordered the tap. A little nervous tackling this on my own.