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Unread 05-01-2013, 08:27 PM   #16
Krom
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Quote:
Originally Posted by js12278 View Post
IMO, those do not look like hairline cracks. They appear to be casting marks.
X2

I looked closely at the pic, and a good allen socket should work just fine on that, after you tap in into the plug with a hammer until it bottoms out. Looks like the wrench wasn't all the way in, and you only stripped the outer half or so

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Unread 05-01-2013, 08:37 PM   #17
ezflip
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Any machine shop should be able to get that out for less than $30. Maybe a couple bucks more since theyll have to do it on their back, but its a super easy, 30 second job for a shop that knows what they are doing.
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Unread 05-01-2013, 09:53 PM   #18
Jeeples
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Had the same problem when I changed the fluid on my wife's WJ. Here's what I did:

Get a drill bit that fits in the center of the rounded out plug (3/8 IIRC), coat it in grease the drill the center out. The grease will help prevent metal shavings from falling into the t-case.

Took the largest easy out that I could fit and removed it using an open ended wrench.
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Unread 05-01-2013, 10:30 PM   #19
perfeng702
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try a punch and a hammer. or use a dremel to slot it and tap with a flathead.
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Unread 05-03-2013, 10:01 PM   #20
as350b3e
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I found someone who is a very competent mechanic (Helicopter and heavy equipment mechanic) that will weld a 10mm allen driver onto the plug.
Got a new plug today and problem is most likely going to be solved.
Thanks all for info.

Enjoy the weekend!
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Unread 05-03-2013, 11:32 PM   #21
PhantomWJ
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Quote:
Originally Posted by as350b3e View Post
I found someone who is a very competent mechanic (Helicopter and heavy equipment mechanic) that will weld a 10mm allen driver onto the plug.
Got a new plug today and problem is most likely going to be solved.
Thanks all for info.

Enjoy the weekend!
I cut a bolt..welded it an now use a socket to remove said bolt/plug
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