transfer case plug replacement

[uss2defiant]

oh.... with the rear and front diff plugs, would anti-seize or teflon tape be recommended to be applied on the plugs too?

Thanks

 

[uss2defiant]

so i failed to get my fill plug out and stopped before i stripped it. the hex was starting to turn a bit in the plug even though i made sure it had seated properly before using a breaker bar.

any suggestions besides heating the case around the plug?
maybe an impact driver, the one used with a hammer? epoxy the hex socket to the plug?

 

[LibertyTC]

Aluminum Transfer case = heat /impacting driver not good..you don't want to crack casing.
However I wonder if a hair dryer warm type heat to plug area would be ok..??
I would not hit it with anything like an impact driver...
Tom or Troy would probably say air tool time.
If they dont reply..... ask for their help by sending em a PM ....
hmmm. maybe there is a reason why Jayme has a 10mm spot welded on....LOL...

 

[yellocoyote]

One too many times being unable to remove it easily... that was enough incentive.

 

[uss2defiant]

One too many times being unable to remove it easily... that was enough incentive.

i take it you brought it to a shop?

 

[uss2defiant]

came across this post by tjkj in another forum

Transfer Case Drain and Fill Plugs are stuck/rusted - JeepForum.com

will that still heat the transfer case up if the jeep is in 2wheel drive?

 

[CactusJacked]

Contrary to what some with less years of experience may be apprehensive about, a propane torch would be my next weapon of choice. Over the past 40 years of using a torch on stubborn bolts and such, and on different metals and alloys, I've NEVER had a negative result. Yes, a torch can get toasty (3,623 F at the inner tip), and the melting point of aluminum is 1,221 F. However, due to heat dissipation, it would take a looooong heating time to get a concentrated area anywhere near the melting point. I would heat the plug directly, which is NOT going to heat up the case anywhere near too hot, then give it a shot from a can of Freeze Off (or canned air). If you think heating it up with a torch is a bad thing, then how hot do you think the red hot plug is getting from being welding upon to attach a bolt or allen wrench to it.

 

[yellocoyote]

i take it you brought it to a shop?

To have the welding done, yes.

 

[uss2defiant]

tried the cooling the plug based on tjkj's suggestion on a different forum as i posted previously but didnt work :\

 

[LibertyTC]

I think it is time to follow Jayme in post 28.
I wonder & hope that .....it has NOT been cross threaded!
At which point being at a shop would be a good thing!

 

[uss2defiant]

yeah. time for some pro help. going to order a set of replacement plugs just in case. i dont know whether the fluid has ever been changed

 

[Mangate]

yeah. time for some pro help. going to order a set of replacement plugs just in case. i dont know whether the fluid has ever been changed

I know how difficult this problem can be. I once had a transaxle drain plug seized in an Alfa Romeo. After rounding out the hex hole, I welded a nut to it then snapped a 17mm spanner with my foot. Eventually I drilled a hole right through the plug and tried a screw extractor or easy out, but with no luck.
That easy out ended up being the drain plug until the day tha car went for scrap years later.

 

[uss2defiant]

sooo haven't had a chance to bring it in to the shop to get this taken care off.
Was googling around and I found this

Lisle Corporation

Anyone used something similar to this?
It has an extractor that would fit a 10mm hex.

 

[Sephiroth]

I ended up using a Multi spline extractor Irwin Industrial Tool 53227 Hex Head Multi-Spline Extractor Set, 25-Piece - Hex Keys - Amazon.com and the help of a bottle jack and some WD-40 (not that the WD-40 did anything) and it came right out.

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[uss2defiant]

I also read from more googling that a pipe nipple extractor might work too.
Cool....
This gives me a little more hope.

 

[uss2defiant]

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Was your plug cross threaded? kinda looks like my water pump threads, all flattened out.

would a scissor jack work? I don't have a bottle jack.

 

[HoosierJeeper]

If it goes high enough it would work. If it's the factory one I don't think it goes as high as that one in the pic.

 

[yellocoyote]

Those threads look pretty gnarled up.

 

[profdlp]

If it goes high enough it would work. If it's the factory one I don't think it goes as high as that one in the pic.

It might if you put a 4x4 under it.

 

[Sephiroth]

Was your plug cross threaded? kinda looks like my water pump threads, all flattened out.

would a scissor jack work? I don't have a bottle jack.

Yes, the shop where I used to get my winter oil changes done completely ruined the plug. My first try was actually trying to hammer in a torx bit (Do not remember what size) but all that did was round the threads even more. Would a scissor jack work? may be, if you lift the jeep you might even be able to use a breaker bar, I used the jack because my breaker bar is a little too long and at 120# I am not strong at all to fight with that plug.

I put the new one in with some teflon tape and a few months later it came out without any trouble.

Good luck.