Topic: Stupid Transfer Case Plug

[Mozman68]

Hex is now rounded out...

I'm guessing my only options are:

1) weld a bolt on to remove...and I don't have a welder...or a bolt..

2). Drill out the center very carefully so I can at least fill it and use a rubber plug temporarily until I can remove the whole thing.

I think it had a slow leak and I was going to make sure it had fluid in it...at least enough to drive for another week until I could drop it off while I'm out of town.

Thoughts?

[Jeffy]

Cut a notch in the side and tap it around?  You could drill two holes stick bolts in them then wedge a screwdriver in there or something else and try to turn it...

[Mozman68]

Hmmmm....may try that.  have a tap I used when I added my rear lights.  I think I even have a couple of extra bolts.

[sharpxmen]

i think you might be able to fill it if you take out the speed sensor, i can't remember exactly but i'm pretty sure it's not on the underside, if it's lateral it might work, only problem is you don't know what the level is.

Jeffy's suggestion with the notch is probably best, just a tiny bit and then use a punch to move it, i took off many rounded bolts like that (usually just use a chisel to put a dent in it and then with a punch just tap it)

i wouldn't drill, no matter how much you try there will still be shavings going inside.

[aw12345]

Try one of these stubby fat easy outs. should do the trick, then use a regular pipe plug to replace the current fill plug. Pretty sure it's 3/8 pipe thread

[Mozman68]

Stubby fat easy out?  Where do I get one of those?  Can't fit screws in there...not sure where I would put them...not enough room on the "rim" of the plug.

[Mozman68]

So...the easy out would drill into the recessed hex area?

[aw12345]

Yup you pound it in there and then spin the thing out.
Your local Sears store should carry those

These are the ones I am talking about, seems like Lowe's carries them too

http://www.lowes.com/pd_62982-281-53227_0__?productId=3732989&Ntt=Easy+out+screw+extractor&pl=1&currentURL=&facetInfo=

[Mozman68]

Damn..that's a nice set.  Checking my local Lowes online now.  Thanks!


Edit:  damn...not available at any Lowes within 45 miles of me. :(

[Bounty Hunter]

Have you tried tapping in the next larger size hex socket?  Or tap in a torx bit that is larger than the hole.  Tap in as far as possible and turn very slowly.

I've got extra rear case halves and plugs if you booger up the parts.

[Jeffy]

Once you get it out replace it with a nut like on the YJ's.  Doesn't require much torque to be tight.

[grumpygy]

Look at Oreilly's Auto Parts Look for Irwin Extractors.

http://www.oreillyauto.com/site/c/detail/IRW0/53226/N0673.oap?ck=Search_extractor_N0673_-1_-1&keyword=extractor&pt=N0673&ppt=C0099

  Just a note this set may not be big enough but they do have them that will work just need to make sure.

[aw12345]

Problem is some steel plugs can get extremely tight in aluminum cases.
Road salt country doesn't help that gig either.
I have had to drill some of those buggers out once the threads start galling it's darn near impossible to screw that plug out.
If you stripped it because it was extremely tight, you just might be in for some extended fun

[Mozman68]

I think I'll stop by O'Reillys on the way home....which is right by Harbor Freight...which is on the way to Sears....someone will have what I need....and if not, I do have huge torx bits in the drawer.

[sharpxmen]

so the plug is not sticking out far enought to be able to try and tap on the edge so it unscrews?
something like this if i can somehow explain properly
   ___
 /       \
|         |
 \ ___ /
         ^
          |
         ^ hammer with a punch here

this works if you can, doesn't take much just a few taps to get it moving.