Bringing this post back from the dead since I just went though this with my 2002. I'm posting this here in case anyone needs any ideas before taking it to a shop for extraction.
I fail to understand why Allen head plugs are used in the front diff case, the head is way too easy to strip if the plug is in there too tight. The fill plug came out easy enough, but when the drain plug starting giving me resistance, I immdiately soaked the area with PB blaster.
I destroyed a 3/8 ratchet when I put a snipe on it, and after that I tried a 1/4 impact driver. All that did was round out the 10mm head without budging the bolt. Anyhow, a buddy of mine lent me a snap on multispline extractor (I really need to pick up a set of these) and it worked like a charm. I will note that the drain plug was sitting with PB blaster on it for about 2 weeks before I got around to extracting it, so I'm assuming that helped.
I figured I should replace both the fill plug/crush washer and the drain plug/crush washer for the low low price of $50CDN (roughly $38USD) from the dealer. Ugh.
Have stripped these on other vehicles owned. I welded in a short grade 8 bolt the fit in the stripped out hole and turned it into something i could get a normal socket on.
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