Front Differential Oil Change Fill Bolt Stripped and other info

Hi all,

I know this has been posted a lot before but I wanted to post again and share some info I think may help other people out here.

So I have a 2018 Toyota Tundra 5.7L CM Limited 4x4 FFV.

I went to do the front differential fluid change. I was able to take off the fill and drain plugs with washers, with 10mm hex allen key socket and was able to drain the fluid. Then I put the drain plug back and torqued it to 29 ft/lbs and put in the fluid. I then went to put in the fill plug with washer and tried to torque it to 29 ft/lbs, but to my surprise, I noticed it went to a point of stiffness and then just kept rotating (this is where it sheared).

I pulled the socket with wrench away and that is where I found out that the plug face was sheared and was into the hex socket while the screw portion was in the front differential cast body. Anyways, I called my local dealer and got the parts ordered and got the old screw portion out with the 10mm allen key and a 4 mm allen key and put the new plug in with a new washer and tightened it till it stopped and then tightened it a quarter turn more and it is all good now.

Here are some pics that I wanted to share with all of you.

Below is the pic of the shear head of the fill plug.



Below is the pic of comparison of old and new washer, we can definitely see the old washer was crushed and that may have been one of the reasons for the bolts to shear? and also the fact that previous owner may have over tightened it?



Below is the pic of the new fill plug. Notice the small hex hole within the bigger hex hole. I observed that the fill plug screw part that was in front differential body could be removed using 10mm hex allen key (I had enough surface area left that I could use it). However, I was also able to use a smaller 4mm hex allen key or 5/32" hex allen key to put in the smaller socket and get the screw part to turn.



Hoping this information becomes useful to future users who run into similar situation.

Also on the parts side, Here is what we may need for the front differential:
90430-24003 - GASKET (FOR FRONT DIFFERENTIAL DRAIN PLUG)
90341-24014 - PLUG (FOR FRONT DIFFERENTIAL DRAIN)
90341-18032 - PLUG (FOR FRONT DIFFERENTIAL FILLER)

$14 12157-10010 Toyota Oil Drain Plug Crushable Steel Gaskets Set of 10 OEM 12157-10010

12157-10010 - GASKET, FRONT DIFFERENTIAL FILLER PLUG

I added the drain plug details as well just in case. Thanks!

 

I am pretty sure you are not the first person on here that this has happened to.