np-242 transfer case fill plug.

skinner · May 6, 2010

OK got this morning to do a oil change and t-case fluid change. went to open the fill plug on the t-case and it is frozen solid. soaked it in pb blaster and tapped on it with a hammer and it will not break loose. Its a 3/8 allen plug that is pretty chewed up so I don't want to make it worse.

here is a pic

after further trying it is now rounded out all together. I have already ordered a new plug but what will be the safest way to remove that damn thing. I may try a extractor first and if that fails drill it out and big as I can tap it and thread another bolt in. unless anyone else has a better idea.

kastein · May 6, 2010

Try cutting notches into it on opposing sides of the hole and then using something as a large screwdriver. Doubtful it'll work...

You could also weld a piece of aluminum stock to the thing and try turning that but that might damage the rest of the case. Luckily it's about a hundred bucks for a whole 242 at the junkyard if you can find one, and a 231 drops in pretty easily if you can't.

ehall · May 6, 2010

heat that sucker up, drive a torx bit into it, and crank it out

Flyfisher · May 7, 2010

If you find yourself in a real bind...I have an NP242 spare...would sell reasonable....plus shipping, of course. HaHa

austinaubinoe · May 7, 2010

when's the last time you changed the ATF? When you do get it open, spread on the anti seize!

RCP Phx · May 7, 2010

austinaubinoe said:
When you do get it open, spread on the anti seize!

Anti-seize would be a bad idea,but Teflon tape would go a long ways!

austinaubinoe · May 7, 2010

sorry for the bad tip... hate to ask whats wrong with anti seize on the t case........

soopergoober · May 7, 2010

You could also try jb welding the allen key in there, let it set, then give it hell? Just don't get any jb weld near the threads.

skinner · May 7, 2010

I got the F'er off took a propane torch and #5 screw extractor to do it but by god its out. LOL.

RCP Phx why is anti-seize a bad idea?

kastein · May 7, 2010

I'm thinking that it's not so good for the transfer case internals once it gets into the fluid, since it contains microscopic metal or graphite particles.

RCP Phx · May 7, 2010

kastein said:
I'm thinking that it's not so good for the transfer case internals once it gets into the fluid, since it contains microscopic metal or graphite particles.

We have a winner!

np-242 transfer case fill plug.

skinner

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kastein

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ehall

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Flyfisher

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austinaubinoe

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RCP Phx

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austinaubinoe

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soopergoober

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skinner

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kastein

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RCP Phx

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