Transfer Case Stuck Fill Plug

[Mudderoy]

Anyone ever have any issues getting the fill plug out of a transfer case?

Drain plug turns fine, fill plug I was starting to round out the middle trying to break it lose!

[abebehrmann]

Mine was stuck pretty good when I first got my Jeep. I tried for a while with a normal Allen wrench before giving up on that because I was worried about wallowing out the plug. Ended up running up to Home Depot and getting the proper sized hex wrench that works with my 3/8'' ratchet, came out a whole lot easier that way.

[Mudderoy]

Mine was stuck pretty good when I first got my Jeep. I tried for a while with a normal Allen wrench before giving up on that because I was worried about wallowing out the plug. Ended up running up to Home Depot and getting the proper sized hex wrench that works with my 3/8'' ratchet, came out a whole lot easier that way.

The 1/2 ratchet and hex socket is what started the problem. :( I'll have to verify the size but there was very little movement, at least when I first put it in there.

I can take the drain plug out with the allen wrench.

[Mudderoy]

Anyone think using a 1/2" impact on that plug would be dangerous to the case?

[4.3LXJ]

You could try it. But personally, I think a little heat with a propane torch would help. And an ice cube on the plug

[blazer2]

I wouldn't use the impact on it.
Mine was metric. 3/8 was a tad to small. Now it's a 1/2"plug so I can put a
Ratchet or breaker bar to get it off. I would use heat

[Mudderoy]

Fill plug removed. Used an air chisel! :flameon:

It was a little low. I removed the front drive shaft so I can replace u-joints as I want without having to crawl under the Jeep.

Ordered a replacement plug to replace the buggered up one. Old one still works though! :D

[cpttuna]

This thread caused me to go out and check mine. Used 55 TORX and had no problem.

[Mudderoy]

This thread caused me to go out and check mine. Used 55 TORX and had no problem.

I never had a problem with either of them until my transmission was rebuilt.

[Mudderoy]

So what's the point of this?

http://i133.photobucket.com/albums/q53/unlimited04/MyJeep/DSC01804.jpg

Seeing the fluid level? Is this a bad idea for an offroad vehicle? Looks like a quick way to drain the case when you don't want to.

[abebehrmann]

So what's the point of this?

http://i133.photobucket.com/albums/q53/unlimited04/MyJeep/DSC01804.jpg

Seeing the fluid level? Is this a bad idea for an offroad vehicle? Looks like a quick way to drain the case when you don't want to.

Yep, I've seen those and I've been told they did it so they could easily check the fluid level. Didn't make much sense to me because I've never had a problem with my transfer case leaking any fluid and it seemed like an easy way to lose all your fluid in a matter of seconds.

[4.3LXJ]

The atlas tcase has one, but involves right angle fittings to keep it closer to the case. It is handy for checking fluid level. I am rigging one up on my OBA compressor for fluid level in it too

[XJ Wheeler]

Seems like it would make filling it difficult.

Sent via messenger pigeon. I talk, he types.

[4.3LXJ]

You pull the hose off the barb and unscrew the fitting. pretty easy. When you drain you can use the hose too

[XJ Wheeler]

You pull the hose off the barb and unscrew the fitting. pretty easy. When you drain you can use the hose too
That's what I was thinking. Just don't want to let that hose dip! [emoji14]

Sent via messenger pigeon. I talk, he types.

[slvmart]

Personally, I would put a bit of anti-seize on any fitting going into aluminum.