Filler plug to t-case stripped

jeepfreak1020 · Oct 15, 2011

So I thought I might change my t-case fluid today. Crawl under the jeep and get ready to start work. Well it looks like the shop that had my jeep a few months ago that had changed the fluid almost stripped out hex that goes onto the filler plug. Well they pretty much had. I throw my hex on there and give it just a little pressure and hex just spins and plug does not. So The hex on the filler plug it stripped. I was able to loosen the drain plug just fine. What do I do now? Because theres no way to get the dam thing out is there?

jeeperjohn · Oct 15, 2011

Well you could weld the hex key to it. :dunno:

jeepfreak1020 · Oct 15, 2011

Cant, you would be welding mild steel to mild aluminum. You cant

banderso · Oct 15, 2011

Case is aluminum, fill plug is steel. You can weld it. I've welded a nut to mine before.

jeepfreak1020 · Oct 15, 2011

O really? You can? I though the filler flug was aluminum to.

ChiXJeff · Oct 16, 2011

See if you can stick a magnet to it.

IIRC, the plugs on my NP231 and NV241 are all steel.

banderso · Oct 16, 2011

I guess it may not be true for all fill plugs, but the one on the 231 in my 91 is steel.

rocknxj · Oct 16, 2011

Plug should be steel. I had the same problem on my first XJ and drilled through the plug. Used heavy grease to trap the shavings. Then I tapped the hoe and used s bolt as a new plug. now I have a welder and recommend welding a bolt or hex to it.

jeepfreak1020 · Oct 16, 2011

well I have a welder as well. So Ill prob just weld my hex tool or a nut to the plug it self. More likely a nut, as I can use the middle of the nut as a plug weld onto the plug. I think that would work. Ill try it tomorrow after work.

cherokeex2 · Oct 16, 2011

If you dont have a welder you can use one of these to get the plug out.

I use them all the time at work when i have to remove stripped plugs.

YuuuuuuuuuuuuP · Oct 16, 2011

I see this all the time @ work, I usually just put the pointed bit on the air hammer and hit it @ an angle much like you would to remove a mechanical fan from the clutch.

Tim_MN · Oct 16, 2011

Re-fill through the Speedo gear opening and call it good.

Grind a 1/2" long bolt to fit into the rounded out hex, weld the bolt to the plug.

Filler plug to t-case stripped

jeepfreak1020

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jeeperjohn

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jeepfreak1020

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banderso

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jeepfreak1020

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ChiXJeff

Curmudgeon

banderso

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rocknxj

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jeepfreak1020

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cherokeex2

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YuuuuuuuuuuuuP

NAXJA Forum User

Tim_MN

Freakish Hand Strength

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