Transmission Fill Plug Rounded

Hello,

I posted this thread yesterday: Transmission Problems Neverending

This morning, I was going to try and resolve the situation. I noticed the Transmission Fill Plug was already a little rounded. I used a 12-point 24mm 1/2" socket and it rounded it more. I stopped - went to the store and got a 6-point 24mm 1/2" socket and after some cursing and putting a lot of body weight into it, I felt it wanting to round too. I've used PB Blaster. I'm at a loss on what to do without making it worse. Any advice or suggestions on how to get this off?

I'm guessing it was already a little rounded from the mechanics that worked on it..

 

I know there’s not enough room in there to do much, but if you can put a claw hammer on its side, on the head. Then wack the claw hammer with another hammer. Sometimes the shock will break the seal. Then try a box wrench.

Or put a smaller socket inside the bolt head and wack the socket hard a few times.
Hold the smaller socket with vice grips.

 

Grind the end of the socket to remove the beveled portion. That will give you more surface area to bite the bolt. Or, do that to a 15/16th socket. That is what I use as I had an extra one laying around, and they are cheaper. At 23.8215mm, it will have a more snug fit than a 24mm socket. If you have a propane bottle, put some heat on the area around the bolt, but not excessive heat as that can cook the ATF.

 

Hammer it directly. It helps a lot with these plugs

 

Funny enough - I found your post about this on TW. I don't have a grinder so I went through like 10 pads of 80 grit on my orbital sander until the head of that decided to bust. I got 70% of the beveled portion of a 24mm 6-point socket off - and it didn't work. It rounded it more so I don't think I have much more things to try until it's completely f'ed. I'll have to go over to a buddy's with that and go buy a 6-point 15/16" and grind both of them - then hammer it, and try it again. If it doesn't work I hope I don't have to resort to an extractor.

 

you can clean it. Wire brush brake cleaner. Heat. Cold spray. AeroKroil.
let brakleen evaporate first it’s very flammable.

Good brand 6pt fits better than crap brand.
Hammer. Twist with sudden shock force. Not gradual arm twist.

I’d try all that first see if it works before other “well that didn’t work” next step methods such as cutting, sanding, grinding, welding, different size sockets, etc.

maybe better or new one handy when it goes back in to not re use a stripped one.

Dont know if a fake weld is as good. Maybe. Like JB weld a sacrificial socket onto there. That will trash the plug. Let it cure. Then try.

or if there’s room to drive to a welder ask how much to weld a socket or something on. Or nut. So you don’t have to buy a welder.
Or if you want to even a cheap welder could suffice for that.

some shops have a little cheap flux core welder for something like this, rather than say high power MIG setup for fabricating things.

 

So - the 15/16" socked ground down past the beveled portions did the trick. I got a 6-point 15/16" socket and I ended up buying a super long-handle Icon 1/2" drive ratchet from Harbor Freight (and a breaker bar if I needed that). I kept putting PB Blaster on it every morning and night, and this morning I hit it about 15 times with a small ball peen hammer, put the 15/16" socket on it, and it came loose with very little effort!!

I still don't have the replacement part in yet (it's on order), so I have to still use it and just barely tighten it past finger-tight. Unfortunately, I have found out that my transmission IS MORE THAN A QUART LOW from the shop that did the flush after I did the correct check procedure. So I need to go get more fluid and pump more in there. Fingers crossed no permanent damage has been done.

Thank you everyone for your help. I was about to resort to heat and then as a last resort - other extreme methods.

 

Maybe return the 24mm socket for a refund?

I don't why Toyota keeps putting using that thin head plug. It is also used on Toyota/Lexus sedans.

Edit: NM about the return. I see above you ground that down also.

 

Unfortunately I had already ground down the 24mm socket the day before, so I'll probably use the 15/16" in the future and the 24 will collect dust. Oh well. I am considering buying an aftermarket plug that doesn't have such a thin head even though I have the OEM one on order for pickup later this week.

 

You can give the 24mm socket to a buddy.

I replaced the oem plug with a Dorman plug. Looking at my Amazon purchase history, I am pretty sure it is part # 65220, an M18-1.5 bolt with a thick 19mm head. I installed it in 2015 and have not had any issues with it.

 

$5 Dorman 65220 Oil Drain Plug Standard M18-1.50, Head Size 19Mm Compatible with Select Models

https://www.amazon.com/dp/B000C14QMK

 

Did you get it out? My suggestions would be first buy an extractor set. Ya know, those extractor sockets with the teeth in them? Worked great for my rounded castle nut…
Also you can tap on it with a chisel to get it moving. Watch a youtube video on it. Search like “seized nut chisel method” or something.

good luck

 

Great trick with the 15/16". Usually, I find that the hex plugs are the biggest PITA but now that I think about it these plugs are thin as well.

 

It saves them $0.005 per vehicle sold.

I hate finding things like that. Then usually the guy before me already rounded it off. Last time, I didn’t have a new plug, had to file the old one to get it tightened down. Then later zip tied the new one next to the battery.

 

Try this: Spray it again with PB Blaster. Let it sit for a few minutes and put a socket on it that fits snug and tap it 4-5 times with a small hammer: don't wail on it, just firm taps. Repeat this ritual several times over a couple of days and try to remove it after each. If it doesn't move: spray and tap again.

This worked for me removing the nightmare plugs on the front differential. (Replaced thereafter with the Lexus plugs.)

 

Appreciate it! This is resolved - I got it loose this morning basically doing pretty much that

 

At the risk of sounding stupid, is there supposed to be anything in these two holes on the transmission up near the fill plug? Just want to make sure the shop that f'd my stuff up didn't remove something and not put it back:

 

The plug is not easy to access for a reason, leave it alone. In the last 9 years I’ve had two Tacomas and driven them a combined 550,000 miles and never did a thing with transmission fluid ever.
Even multiple money-hungry Toyota service techs advised against it…

 

They overtightened it.

The aluminum washer is pretty thick, it just needs to be squeezed a little bit

Overtightened fasteners is a sure sign of inexperience