Hilux 4x4 Forum

With my 170000km service, I damaged the gearbox fill/check plug on my 3.0 D4d Hilux. That is one area that I don't like Toyota's design, are the fill plugs on the transfer and gearboxes. So I first tried to tap it loose with a chisel, but with no success. Also scared that I would damage or crack the gearbox housing.
Then I welded a nut on the plug with a TIG welder after removing the battery terminals of course.
Finally it came loose very easily.
It helps to remove the diesel cooler for a bit more room to work. I the replaced the fill plug with the one you will see in the photo. Much better as it has more meat where the socket or spanner can grip on.

I tried placing the photos inline but when I click on preview, the disappear.

One way is ....

• to click on "Edit" and select all the text that's between [img] tags and delete. Go back to "Attachments - "Add files" and your uploads will still be there. Scroll back up to the text box. Place your cursor where you want the images below your text and then scroll back down to your uploaded images and click on "Place in line" for each one in the order that you want them to appear.

The other way is ....
• to click on "Edit" and select the individual image texts and cut / paste them into the correct order in the text box.

I assume that the last image should have been the one to display first but that the rest are in the correct order (that's how it places them by default for some reason if you haven't placed them before submitting).

I had a quick look ..... cannot do either of what I described above because it appears as one single image. Strange.

Thanks for checking Andy. I emailed the photos form my phone to myself to get it on my pc. And when I downloaded it, it saved it in my downloads folder as one zipped file. Strange. Maybe thats why it doesn’t want to work.

Any way. Hope this post can help someone with the same problem on the fill plug.

Hau!

I deleted and reloaded your images, placed them "in line" in numerical order (which is what I assume you wanted) and submitted. They come up in the right order as placed, but the deleted ones are still there .... something strange happening ... I also notice that they are not between the normal [img] tags, but are now called attachments.

Maybe the zipping had something to do with it .... gonna go check on some other posts ......

You can replace the filler plug with a camry one, that has a female 10mm allen socket, which works much better and doesn't strip easily.

viewtopic.php?f=92&t=36185&p=431587

That is a good idea Nic. I have a dedicated socket where I grinded the shoulder on the mouth flat to ensure that I get the maximum bearing surface between the socket and the plug and I have only had one issue to date on a Triton where the plug was already damaged. I find that because those plugs are normally tightened from below the vehicle by the local service technicians assistant, where they have a good grip on the spanner and their body weight to help that these plugs are very often over tightened. Bottom line is I always prepare for the worst when I need to undo those plugs.

A wack with a hammer is always a good idea when the bolt and the thing it screws into are different metals (steel and aluminium in this case), it helps reduce the sticktion. That and copper slip are your friend