242 Fill Plug Is Stuck!! - JeepForum.com
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post #1 of 26 Old 11-25-2015, 06:32 PM Thread Starter
tetatdo
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242 Fill Plug Is Stuck!!

Trying to add some fluid to my 242, I _cannot_ for the life of me get the top fill bolt to come out! Tried with a 30mm socket, tried heating it and banging on it with a long 30 mm wrench and a mallot. All I am doing is stripping it.

How do you get this damn thing off?!


Tetatdo
94 ZJ 4.0L/NV242 WJ Manifold, 63mm TB, Kolak 2.5" Exhaust, 703 Injectors, SBEC-II Tune
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post #2 of 26 Old 11-25-2015, 07:04 PM
kg6mov
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At this age they don't tend to come out easy. Heat helps, patience.


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1984 F250, 460 BB, T19, work truck/future tow pig
1987 Mercedes 300D Turbo, the diesel daily, 30mpg in style

Quote:
Originally Posted by Texas ZJ1 View Post
I heard someone yell "mall crawler" from the back porch. I'll go see who said that. Be right back.
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post #3 of 26 Old 11-25-2015, 07:26 PM
dan66cj5
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I had to use my 1/2" air impact wrench on mine.
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post #4 of 26 Old 11-25-2015, 08:43 PM
MurdaJs
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If you can't get her off you can use the vent tube on top of the tcase to add fluid
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post #5 of 26 Old 11-25-2015, 08:49 PM
MKCoconuts
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I thought the fill and drain plugs were 10mm allens? They are on mine at least. Use heat and if you can find it, CRC "Freeze off". Spray it and then bang a little with a hammer to try and break it loose.
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post #6 of 26 Old 11-25-2015, 09:31 PM
kg6mov
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Early cases are 30mm, late style are 10mm allen.


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1984 F250, 460 BB, T19, work truck/future tow pig
1987 Mercedes 300D Turbo, the diesel daily, 30mpg in style

Quote:
Originally Posted by Texas ZJ1 View Post
I heard someone yell "mall crawler" from the back porch. I'll go see who said that. Be right back.
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post #7 of 26 Old 11-26-2015, 02:35 AM
Uniblurb
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Since steel and aluminum don't like each other those plugs will often seize/corrode in. I've always taken a sharp razor knife and gone around the plug right where the threads are to cut through the fine crust. Believe this may help the rust cutter penetrate better.

I've also used heat around the plug but you have to watch you don't start melting the aluminum. Once hot I'll also shock it with some PB but try not to breath that smoke. Have had to go back forth heating/rust cutter a few times when seized real bad. Good luck.

96 4.0 ZJ Laredo, 2004 4.7L WJ Limited, 93 4.0 XJ (spare), 96 4.0 XJ (son's)


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post #8 of 26 Old 11-26-2015, 04:16 AM
Timo_90xj
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..and when you re-install after (hopefully) getting the fill plug off, be sure to coat the treads with anti-seize or copper paste. Also, do NOT overtighten. The fill plug doesn't need to be tightened much at all, basically just enough so it won't unthread by itself.

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...


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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

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post #9 of 26 Old 11-26-2015, 11:07 AM Thread Starter
tetatdo
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thanks for all the tips, guys! I ended up putting the ol' ZJ into long term storage yesterday, next time I need to drive it, I'll try using all your tips to get it loose.

Tetatdo
94 ZJ 4.0L/NV242 WJ Manifold, 63mm TB, Kolak 2.5" Exhaust, 703 Injectors, SBEC-II Tune
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post #10 of 26 Old 11-26-2015, 01:52 PM
kwellzz
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For future JF visitors to this thread...Never remove the drain plug without knowing the fill plug will come out first.

Denver Motorcycle Repair
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post #11 of 26 Old 11-26-2015, 05:31 PM
cwness
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To stop from stripping it I only use a 6 point socket and a breaker bar. I sprayed it with PB blaster first and let it sit over night. I tapped on the bolt
a couple of different times to get the PB to work penetrate better. Came right out the next morning.

CW
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post #12 of 26 Old 12-12-2015, 04:32 PM Thread Starter
tetatdo
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man i tried EVERYTHING, it wont work!! It is now completely stripped. I even tried a monkey wrench, cant get around the fill hole, too many other protrusions. What to do?

Tetatdo
94 ZJ 4.0L/NV242 WJ Manifold, 63mm TB, Kolak 2.5" Exhaust, 703 Injectors, SBEC-II Tune
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post #13 of 26 Old 12-12-2015, 04:43 PM
dan66cj5
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Drill and tap a new hole ?
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post #14 of 26 Old 12-12-2015, 04:54 PM
kwellzz
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Drop your tc

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post #15 of 26 Old 12-12-2015, 08:28 PM
Uniblurb
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The plug had started stripping when you started this thread and was it a 12pt 30mm socket you were using rather than 6pt? I didn't even like the small bevel on the 6pt impact socket I bought and ground the nose of the socket off flat since know that nut grip on the plug doesn't stick out very far.

If you know somebody with a portable welder they may be able to tack weld a nut on the current plug if it doesn't harm the aluminum case.

Or like MurdaJs mentioned fill it through the vent hole in the top of the case. Capacity is 1 1/2 qts for the 242 and most use ATF+4. At least you could drive it and take it to a shop to get the plug out if that's your last option. Good luck.

96 4.0 ZJ Laredo, 2004 4.7L WJ Limited, 93 4.0 XJ (spare), 96 4.0 XJ (son's)


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