T-Case Fill Plug??!!!HELP

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HenryKrinkle

NAXJA Forum User

Location

WI

• Jul 26, 2009

• #1

I was changing gear fluids yesterday and like an IDIOT, I drained the transfer case without loosening the fill plug. Now the damn fill plug won't budge. I soaked in PB blaster all night, tapped it firmly with a ball peen, and nearly stripped it with a crescent wrench. I know the crescent wrench is no good for this stuff, but it's the only thing I had that fit. I think I need to go buy a socket big enough.

Is the fill plug the same size as the drain plug? (to go buy socket)

Should I heat it with a torch/soldering iron? (to break any loctite)

Anyone have any tips? (Need this fixed ASAP!)

 

cabjeepster

NAXJA Forum User

Location

Flora,Indiana

• Jul 26, 2009

• #2

Im pretty sure the size is 1 3/16.

 

NW-ZJ-SCOTT

TEXAS-JT-SCOTT

NAXJA Member

Location

NE Texas

• Jul 26, 2009

• #3

my fill plug is a 30mm

 

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HenryKrinkle

NAXJA Forum User

Location

WI

• Jul 26, 2009

• #4

I have the selecttrac, np242 I think...

 

NW-ZJ-SCOTT

TEXAS-JT-SCOTT

NAXJA Member

Location

NE Texas

• Jul 26, 2009

• #5

same here.. 30mm..

 

L

lawsoncl

NAXJA Forum User

Location

North Idaho

• Jul 26, 2009

• #6

nw-xj-scott said:

my fill plug is a 30mm

Click to expand...

Yup 30mm. A 1-3/16" is close enough if you have one (30.1625 mm).

Worst case, just roll the Jeep over and fill it back up. :}

 

H

HenryKrinkle

NAXJA Forum User

Location

WI

• Jul 26, 2009

• #7

Got the 30mm at ACE, still won't budge... Heat? The case appears to be alum, so heating the steel plug may just get it stuck harder. I'm hunting for a piece of pipe to use as a breaker bar...damn

 

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wim hoppenbrouwers

NAXJA Forum User

Location

Netherlands europe

• Jul 26, 2009

• #8

HenryKrinkle said:

Got the 30mm at ACE, still won't budge... Heat? The case appears to be alum, so heating the steel plug may just get it stuck harder. I'm hunting for a piece of pipe to use as a breaker bar...damn

Click to expand...

Hallo. Try to warm up only the alum case around the bolt.
Keep the bolt so cold as possible. :yap:

p.s.Old school idea::Flatten the socket with a grinder, when the fillplug is became round. The socket will go deeper (edge is sharper) on the bolt and you have more grip.


'92 XJ

 

Last edited: Jul 26, 2009

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rysam

NAXJA Forum User

Location

Paradise, Ca.

• Jul 26, 2009

• #9

giving the ratchet/breaker handle a few whacks in the direction of looseness with that ball peen should help break it loose. you risk ruining your ratchet if you whack it too hard it so i recommend the breaker instead.

 

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HenryKrinkle

NAXJA Forum User

Location

WI

• Jul 26, 2009

• #10

Crisis averted! Used an old hollow barbell as a breaking bar. Leverage is key!

wim hoppenbrouwers: The first thing I thought of when I bought the socket was to grind it down and eliminate that chamfer, unfortunately my grinder is 3 hours away right now. Thanks for the tip though.

Anyways, thanks to all for the help and putting up with the new guy...I look forward to the day I can pony up for a membership....