I have been through this before but not on my PoPo,I soaked it with PB Blaster and used a tad larger star "torx bit" than the actual rounded allen plug and lightly tapped it in with a small ball ping hammer until it bottomed and used a ratchet to remove it,most get resessed down into the hole when tightned and impossible to get a chisil to.That worked for me?

 

I'm not entirely sure if your 800 deluxe has the same front diff as my 500 deluxe but the part number for mine was napa p/n 704-1344 3/4-16 1" hex head. Hope this helps.

 

79hugger, I've used that same method on numerous rounded allen plugs over the years. IMHO, this is the best method (and safest).

 

I was gonna try that so I went to Canadian tire to pick up a set of torx sockets (don't have the right size) that were on sale for 75% off, ofcourse they were sold out.... will have to try later in the week, the new plug will take 5-7 days to get here.

On the bright side, I drained my tranny and the oil was fine, thought it had water in it because if was running out the fill plug.. guess I must have overfilled it last time.

 

Weld a nut on the end of the plug to get it out or to make it permainrnt thats what i did and it never failed yet.

 

I'm thinking I use a 3/16" allen on my 500,not metric but I'm sure they have changed over the years.I have a set of metric and std impact hardened torx bits "Harfor Freight Specials" some I've tapered at the tip with a file to make it easy to enter stripped out allen bolts/plugs.I found the cheap non heat treated type will break off easy