transfer case plug replacement

[uss2defiant]

Hi all,

I attempted to replace the transfer case fluid but failed to undo the fill plug.
I'm hoping I can remove it with some PB but it looks like I might have to remove the skid plate to get more torque on the plug.

I found an old thread on the forum citing a lost post regarding replacing the plugs that will fit a 19mm socket instead of a 10mm allen wrench.

Here's the lost post
LOST JEEPS • View topic - NV 242 darn 10mm allen plugs!!!!

Here's the NAPA part it refers to
NAPA AUTO PARTS

Changing it to a nut instead will allow me to use an extension in the future to avoid removing the skid plate.

1. Has anyone replaced their transfer case plug? if so what did you use?
2. the posts on lost seem to indicate that the gasket w/ the plug is not suitable. someone mentioned copper washer but I guess I could use some teflon tape??

Any other thoughts/comments?

thanks.

 

[CzarKJ]

Hi all,

I attempted to replace the transfer case fluid but failed to undo the fill plug.
I'm hoping I can remove it with some PB but it looks like I might have to remove the skid plate to get more torque on the plug.

I found an old thread on the forum citing a lost post regarding replacing the plugs that will fit a 19mm socket instead of a 10mm allen wrench.

Here's the lost post
LOST JEEPS • View topic - NV 242 darn 10mm allen plugs!!!!

Here's the NAPA part it refers to
NAPA AUTO PARTS

Changing it to a nut instead will allow me to use an extension in the future to avoid removing the skid plate.

1. Has anyone replaced their transfer case plug? if so what did you use?
2. the posts on lost seem to indicate that the gasket w/ the plug is not suitable. someone mentioned copper washer but I guess I could use some teflon tape??

Any other thoughts/comments?

thanks.

Ya I had no issue getting mine out with a little pb. Drop the skid to get to it that's very easy and keeps the job clean. Teflon tape will keep it from sticking and leaking for next transfer.

 

[uss2defiant]

I see. Teflon tape both plugs I take it?

 

[CzarKJ]

I see. Teflon tape both plugs I take it?

Yes

 

[LibertyTC]

Hmmm..The Teflon tape sounds interesting...
I just used a small booger of anti-seize wiped on the threads on the transfer case plugs.

 

[CzarKJ]

check out Flair's video. Don't mind the sounds though haha.

http://www.jeepkj.com/forum/f202/satchel-mcqueens-how-video-section-54073/

 

[uss2defiant]

check out Flair's video. Don't mind the sounds though haha.

http://www.jeepkj.com/forum/f202/satchel-mcqueens-how-video-section-54073/

Yep. I already have that video bookmarked! However, I think he only had teflon tape on the drain plug.
Also have his diff. gear oil change youtube vid bookmarked too!
Pulling out the orange was funny.

 

[yellocoyote]

I had a 10mm hex head welded on so I could use a socket to remove it. It was stuck a few too many times for my liking. Now I have no issues removing it.

 

[uss2defiant]

hmm........
so no one in the forum has changed up their plugs?

I guess maybe it's not something that gets changed frequently and doesn't cause an issue.

 

[LibertyTC]

Jayme made it easy with a hex head welded in place. Always remove the fill plug first...
Oh and the fill & drain plugs are 15-25 ft lbs of torque.
With some anti-seize on the threads, mine unscrews easily.
I luckily have an adjustable long handle ratchet in 3/8 with a 10mm as seen below..
50607[/ATTACH]"]

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Even though a longer 10mm Allen key can do it, this ratchet makes it so easy to apply some torque to remove plugs.

 

[uss2defiant]

Jayme made it easy with a hex head welded in place. Always remove the fill plug first...
Oh and the fill & drain plugs are 15-25 ft lbs of torque.
With some anti-seize on the threads, mine unscrews easily.
I luckily have an adjustable long handle ratchet in 3/8 with a 10mm as seen below..
50609[/ATTACH]"]

You must be registered for see images attach

Even though a longer 10mm Allen key can do it, this ratchet makes it so easy to apply some torque to remove plugs.

Yeah.... I'm considering buy one w/ 10mm hex on a socket.
Doesn't anti-seize change the "torque responds" on the plug?

 

[LibertyTC]

Just the way the plugs seats generally means you are going to have to break them free.
As far as changing the torque values possibly, but keep in mind I dont go crazy with the anti-seize we are talking a light sniff of it only.
Once the plug is out, I clean the threads on both sides with alcohol using a precision tip Q-tip.
I use my finger to apply the anti-seize all around on the plug, & then lightly wipe it down with news paper or a paper towel to remove excess.
Then install the plug.
Here is one of the hex sets in 3/8 I found useful....
50611[/ATTACH]"]

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[uss2defiant]

argh...... PB blaster overnight and this morning didn't work.
I went to HF last night to buy a hex socket but still could not get the fill plug unscrewed.
Need to buy a socket adapter to use the loaner 1/2" socket breaker bar.
missing my 1/2 to 3/8 adapter.

Bah.......

 

[LibertyTC]

I think I have what You Need!
50653[/ATTACH]"]

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I do buy sets for a reason....
Hope you get the breaker with adapter to loosen that really tight... plug!

 

[uss2defiant]

hahhahaha wish you were my neighbor

yeah..... going to have to make another trip to harbor freight to buy a set of adapters.
Well I get to pick up another free item.

I hope the breaker bar will work without me jacking the jeep up. I fear it might break loose and I would crush my fingers and the exhaust with the bar.
>.<

I was hoping to see the 'miracle" of PB blaster this morning.

I wish there were garages here available to work on the jeep like makerhouses popping up all over the place.

 

[LibertyTC]

This is where a set of ramps would help out. You could borrow any tool you want...
Or you could have me come over and fix it. I guarantee that it will be free in seconds...
50655[/ATTACH]"]

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[uss2defiant]

yeah... it's on my shopping list. kinda hard to have those in an apartment

oh boy... can't wait to do the front and rear gears.
don't know whether I want to do the transmission by myself anymore >.<

 

[LibertyTC]

And it all begins by....
50657[/ATTACH]"]

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If you are stock why would you want to re-gear? Are you planning lift/big tires?
Whats up now with the transmission? Or you just need a pan drop for fluid/filter?
You got skids? BTW where is a photo of Your Jeep??
Digging serious into that kinda work requires specialty tools & a lift/hoist etc is highly recommended !

 

[uss2defiant]

oh sorry, I meant changing the fluids for the transmission and gear

 

[dude1116]

I tend to put a long socket on the end of an extension and slip that socket over the long part of the allen wrench. Kinda acts like a little tortion bar. If you have a strong enough allen wrench, it SHOULDN'T break (I HAVE broken one fairly thin, fairly cheap wrench).