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Author Topic: Stupid Transfer Case Plug  (Read 5268 times)

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Offline Mozman68

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Re: Stupid Transfer Case Plug
« Reply #15 on: September 10, 2012, 11:58:00 AM »
yeah...maybe 1/16" at most proud of the case.  Would have loved to be able to clamp the outside and turn.
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Offline sharpxmen

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Re: Stupid Transfer Case Plug
« Reply #16 on: September 10, 2012, 12:13:06 PM »
Quote from: Mozman68 on September 10, 2012, 11:58:00 AM
yeah...maybe 1/16" at most proud of the case.  Would have loved to be able to clamp the outside and turn.

you can still try, make a small notch enough so that you can try and move it some, it's worth a shot imo
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Offline VA_YJ

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Re: Stupid Transfer Case Plug
« Reply #17 on: September 10, 2012, 12:25:38 PM »
Here's something else to try:

1. Using a hammer with a flat face, tap the hex plug firmly to push material back into the hole.

2. Make sure the hole is cleaned out all the way to the bottom (no mud, crud, etc.).

3. Drive a hex bit socket into the hole until it bottoms out.

4. Turn evenly and slowly - a "T" handle wrench works well for this.
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Offline Bounty Hunter

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Re: Stupid Transfer Case Plug
« Reply #18 on: September 10, 2012, 12:31:39 PM »
Don't be afraid to notch the plug with an angle grinder, enough to drive it out with a chisel.  Heat from an LP bottle may help as well.
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Offline VA_YJ

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Re: Stupid Transfer Case Plug
« Reply #19 on: September 10, 2012, 12:33:21 PM »
Oh, let's not forget the PB Blaster...
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95 YJ, 31 BFG ATs, 4.0 TB & spacer, Banks header, DynoMax CAT back, 19# inj, AEM CAI, 20 gal mod, Optima yellow
98 TJ, 35 BFG Krawlers, 4.0 liter, ax15, atlas 5:1, armor, Super 88 (under construction)
96 XJ Cheep Cherokee, 33s, 4.0 liter, AW4, future project
89 Waggy, 360 V8 727 dana 44s, it runs

Offline neale_rs

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Re: Stupid Transfer Case Plug
« Reply #20 on: September 10, 2012, 12:33:39 PM »
Using a punch is very effective.  With a pointed punch you can hammer it in a bit, then turn it a little sideways and hit it with a hammer to get the plug to turn.
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Offline Mozman68

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Re: Stupid Transfer Case Plug
« Reply #21 on: September 10, 2012, 01:50:45 PM »
I should also mention I'm trying to do all of this without removing the ungodly heavy Full Traction skid plate.

The easy out may be my best choice for this reason alone.
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Offline Jeffy

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Re: Stupid Transfer Case Plug
« Reply #22 on: September 10, 2012, 03:05:50 PM »
Yell at it... till it falls out...
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Offline Mozman68

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Re: Stupid Transfer Case Plug
« Reply #23 on: September 10, 2012, 03:31:23 PM »
Picked up a 3/8" breaker bar at Harbor Freight...just cause I didn't have one....as well as a extractor kit.

Then ran by O'Reilly's anyway and picked up a #7 extractor just in case I needed a bigger one.

Then the Jeep dealership was right up the road from there....picked up two filler plugs (just in case)..$5 for both!
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Offline Jeffy

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Re: Stupid Transfer Case Plug
« Reply #24 on: September 10, 2012, 04:01:21 PM »
Did you get the old style or the new one?
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Offline Mozman68

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Re: Stupid Transfer Case Plug
« Reply #25 on: September 10, 2012, 04:39:06 PM »
The same, new, recessed 10mm hex one...I'll just make sure not to over tighten this time.....
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Offline Jeffy

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Re: Stupid Transfer Case Plug
« Reply #26 on: September 10, 2012, 04:43:17 PM »
Quote from: Mozman68 on September 10, 2012, 04:39:06 PM
The same, new, recessed 10mm hex one...I'll just make sure not to over tighten this time.....
You could add some anti-sieze to it as well.  The plug doesn't need to be that tight though.  just enough not to leak.  I never check the torque on mine since I'm using a large adj, jaw wrench.
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Offline Mozman68

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Re: Stupid Transfer Case Plug
« Reply #27 on: September 10, 2012, 05:22:29 PM »
Looks like they have anti seize on them already...still drinking beer...will head out in a bit to get the old one off.
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Offline Jeffy

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Re: Stupid Transfer Case Plug
« Reply #28 on: September 10, 2012, 05:57:31 PM »
Well, you don't want to chance spilling that now...
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Offline Mozman68

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Re: Stupid Transfer Case Plug
« Reply #29 on: September 10, 2012, 05:59:27 PM »
I like to have at least two beers in me before I start drilling into major drive components of my Jeep...
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