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Unread 05-01-2013, 03:01 PM   #1
as350b3e
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Transfer Case Filler Plug

The plugs allen is worn out and I can not remove the filler plug......What can be done?

How difficult is it to remove the Transfer Case and replace the cover with a new one? Is it even possible to remove the cover without removing the transfer case?

How about those hairline cracks, no leaks yet but are these common?

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Unread 05-01-2013, 03:05 PM   #2
Upside
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There is a thread online about disassembling a 242 in the vehicle. Not sure I'd want to do it that way but it's possible. I can't see your pic, is the plug stripped?
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Unread 05-01-2013, 03:12 PM   #3
billzcat1
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Hammer the next size larger Torx or triple-square socket into it. Heat up the surrounding case area with a torque and remove the plug. Replace the plug with a new one.
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Unread 05-01-2013, 03:18 PM   #4
as350b3e
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Won't hammer somthing into it damage the cover of the case? I guess the plug is aluminum, right?
What is a triple square socket? Never mind, I googled it....
Can you guys see the picture now?
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Unread 05-01-2013, 03:19 PM   #5
ChrisHager
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What billzcat1 said...

You could also attempt to weld a nut on top of the plug. After a good weld, remove the plug with a socket.
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Your symptoms sounds just like what it does when it's not doing what it should because of how it is.
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Unread 05-01-2013, 03:24 PM   #6
Upside
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I can see the pic now, might have been related to me being on the mobile site. As Billz Said try tapping in the next size larger bit and applying heat. I've also had luck using a reversing impact drill with a bit to back these out.
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Unread 05-01-2013, 03:24 PM   #7
as350b3e
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I understand but there are hairline cracks around the base of the plug, worried I will break the cover.......
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Unread 05-01-2013, 03:32 PM   #8
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Buy a 3/8" drive hex bit, tack weld it into the plug. Similar to the nut idea, but gives you more room to play. The cracks don't look significant to me.
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Unread 05-01-2013, 04:01 PM   #9
as350b3e
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Ok, thanks I will wait with this since I have to drive the WJ next week 500km to catch a plane to Europe, can't miss my flight!!!!

I have no welding equipment nor a torch and the shop rate is C$200 where I live, sucks I know.......
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Unread 05-01-2013, 04:04 PM   #10
USFORCES
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It don't look stripped to me, sure your using the correct allen wrench?

Anyhow yeah I like the welding idea better...
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Unread 05-01-2013, 05:14 PM   #11
as350b3e
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Yeah I was, 10mm Allen. The drain plug fits perfectly.
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Unread 05-01-2013, 05:42 PM   #12
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You need a "Hanson Hex Head Multi-Spline Screw Extractor" size: 7/16. It is a stubby reverse thread extractor that with a 16mm socket and breaker bar will remove the plug easily. I just did it last fall. Use a hammer to lock it into the stripped hole and twist it out. Use my description and search Amazon. I bought mine for $11 shipped.
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Unread 05-01-2013, 06:21 PM   #13
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Originally Posted by as350b3e View Post
I have no welding equipment nor a torch and the shop rate is C$200 where I live, sucks I know.......
In a pinch you could grab some car batteries and make an instant spot welder (and yes this does work)

http://www.ehow.com/how_4857206_spot...r-battery.html
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Unread 05-01-2013, 06:32 PM   #14
as350b3e
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Thanks FlyRLo, but I think I go with dagmando's solution or remove the cover since i want to stop the leak from the Transfer case.

Kind of look forward to work on the transfer case!
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Unread 05-01-2013, 06:44 PM   #15
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IMO, those do not look like hairline cracks. They appear to be casting marks. I would suggest the ez out idea as well. If that doesn't work, spot weld the 10mm hex key in there. If you can't spin the hex key because of space limitations, cut off the excess and use a socket to back it all out.
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