Can’t remove rear diff drain plug

I’ve done a decent amount of rock crawling in the 4Runner and thought a rear diff skid was a waste of money since the rear is all steel. But a few months ago, I went to change the fluid and noticed I couldn’t get a socket on the drain plug since the “surround” had been pushed against the plug. And now the plug started leaking after my most recent Offroad trip.

Is it my best option to fix this by welding a nut onto the plug to remove it? Then grind the “surround” until there’s clearance for a socket? Or should I notch the plug and try to chisel it to loosen it—worried I may not be able to break it loose this way.

Definitely buying a diff skid after I fix this

 

^It's leaking because the rocks caught a corner of the plug and slowly loosened it after repeated hits. Try chiseling first, if insufficient, grind the plug until you can fit a 24mm socket on it.

The rock crawling circles have come up with an allen socket magnetic drain plug Trail-Gear P/N 140032-1-KIT for this purpose. I'm using one as a hand-me-down part from my Tacoma:

 

I would just deburr the area to give you access with socket.

 

Weld it closed and drain/fill from the top hole.

 

I’m going to order this plug! Thanks!

I’ll see if I can grind the surround without removing the plug but didn’t think I had any bits small enough to do so.

Maybe I don’t need to spend $300+ on a diff skid now….

 

Don't Allen head bolts have a tendency to strip out if difficult to remove?

 

^Factory ones can be difficult to remove because they're installed dry and rust in place. If you're installing one yourself after draining the diff oil, the threads will be coated in oil, and subsequent removals won't be difficult. Just hammer in a good 10mm allen bit for removal.

 

Maybe a thin walled socket???
Or a combination of a little bit of grinding and a thin walled socket?

 

In looking at the link you provided, it looks to be made out of hardened metal, like impact sockets, so it doesn't seem it would strip out.

 

I would grind the mangled surround away from the bolt with a dremel until you can fit a socket on it.

 

I used a cold chisel to cut away the metal that got dragged inside the ring. Couple of minutes work and I could slip a socket onto it.

 

It has a black oxide coating. No idea if the steel used is harder than OEM. The magnet is stronger than OEM though.

 

This. Use a Dremmel tool and grind enough away so you can get a socket on it.

 

Have you tried a dremmel. Lots of cutting and grinding attachments that are small and can remove the steel pushed up to the plug and blocking your socket.

 

Finally got around to removing the drain plug by tapping it with a hammer and chisel. Then grinded the surround back a bit. Wish I didn’t since I ended up nicking the mating surface a bit. Installed the 10mm hex head drain plug recommended in this thread. No more leaking!