The square end of the dif drain plug on my 1994 4/4 has been destroyed, either by speed bumps or heavy handed spannering. Has any one else had this problem and have they come up with a clever solution? Thanks

Depending upon how bad it is you could:

(a) square it back up and get a smaller spanner on it.

(b) get a small set of stillsons on it.

(c) drill it and use a screw extractor on it.

Could you post a photo of it?

Thank you tmg513 I have tried a & b and it has just destroyed the plug further. I suspect I will have to take the axle out and drill do you know if you can remove the axle without taking the brake back plates off? Thanks

Can it not be done with the axle in situ? I think I'd be inclined to find a friendly local mechanic and get him to put it up on a lift and see if he can sort it. Obviously you'll need a replacement plug first.

Try a pipe wrench, it will do it.
Ken in Sweden

one little trick we used to do, especially easier once Mig welders were made available (brazing prior to that) was to weld a NUT onto the effected stud VUOLA a new head available to your spanner, also the slight heat consentration to the area helped

Heat is the key to this. Heat plus mole grips are my favourite fix. It's probably been overtightened in the past.
No need to get the axle off.

I would go for mig welding a nut onto it as well. I have sucessfully use this on buggered up locking wheel nuts many times.

As Ken mentioned I would try a pipe wrench (Stilsons) first. I would be surprised if you couldnt move it with this providing you have enough room to get a good purchase on the damaged square end.