Bolt welded in transfer case fill plug

[Link]

If you have an electric heat gun, use the high heat setting and heat the aluminum. It'll expand and make it easier to come out.

What I did....I heated it up with a heat gun at first, then a torch....used very very carefully. Then, spray with water to shock cool it. Did that a couple times. Also helped clean out the plug for welding. Then, ground down a bolt till it was a snug fit into the fill plug. Tapped the bolt in and welded it with a MIG welder. Sprayed it down again with water to cool it. Then, heated it up with the heat gun on the aluminum. Twisted right out without a problem.

 

[lowell66dart]

If you have an electric heat gun, use the high heat setting and heat the aluminum. It'll expand and make it easier to come out.

What I did....I heated it up with a heat gun at first, then a torch....used very very carefully. Then, spray with water to shock cool it. Did that a couple times. Also helped clean out the plug for welding. Then, ground down a bolt till it was a snug fit into the fill plug. Tapped the bolt in and welded it with a MIG welder. Sprayed it down again with water to cool it. Then, heated it up with the heat gun on the aluminum. Twisted right out without a problem.

Get a raw steel (not galvanized) fender washer with a 3/8 hole. Your going to have to get creative with the ground clamp but lay that washer over the plug and weld up the center. Then weld a nut to the washer. All the welding will be all you need to heat things up. It may take a few try’s but this method has never failed me.

 

[Obi-Wan]

Bad lighting, but it sticks out a good 6 inches.

Now is not the time to start bragging, this man needs his T-case fixed.

 

[C.J. Roberts]

Bad lighting, but it sticks out a good 6 inches.

Now is not the time to start bragging, this man needs his T-case fixed.

Six inches isn't bragging. It's a cry for help.

 

[TheBoogieman]

I want to see pictures of the guy that sold you this Jeep. He did something that caused him to replace a 241 with a 231, then screwed up the fill plug on that.

 

[06TJRubi]

I want to see pictures of the guy that sold you this Jeep. He did something that caused him to replace a 241 with a 231, then screwed up the fill plug on that.

You and me both! It’s weird bc the rest of the Jeep seems to be well taken care of, and no rust, etc. I’ve already ordered new fill plugs and some Redline .. maybe next pay check I’ll look for a 241

 

[mrblaine]

maybe next pay check I’ll look for a 241

You are very well paid.

 

[06TJRubi]

You are very well paid.

Wow didn’t realize they were that much ..edit: “next multiple pay checks”

 

[TheBoogieman]

Wow didn’t realize they were that much ..edit: “next multiple pay checks”

Now, do you see why the PO did what he did? That still doesn't excuse it. I can get a used 231 for under $500.
https://www.ebay.com/itm/3154209151...pid=5337789113&customid=&toolid=10001&mkevt=1
p.s. If no doctors can fix my back issues and I have to sell my Jeep, we can trade transfer cases

 

[chaseb913]

What about just buying a used rear case half ? They seem to run pretty cheap on eBay.

 

[JEEPCJTJ]

What about just buying a used rear case half ? They seem to run pretty cheap on eBay.

That would just barely improve his 231.

As for the guy that swapped to the 231 it could be that he got it with that boltplug< and just figured, "I don't care about that, i'll just leave it there to screw the next owner."

 

[mrblaine]

Wow didn’t realize they were that much ..edit: “next multiple pay checks”

Yep, and as Boogie stated, that cost is very likely the reason you are dealing with a 231. 1 of 2 things probably happened, got ready to sell and offered it as a swap out with a 231 in trade for a lot of money, or they ignored the double cardan making noise when they shouldn't and it locked up and in turn exploded the case.

If you will weld a 10mm hex coupling nut into that plug, it will screw right out if you get on it while it is still hot.

 

[06TJRubi]

That would just barely improve his 231.

As for the guy that swapped to the 231 it could be that he got it with that boltplug< and just figured, "I don't care about that, i'll just leave it there to screw the next owner."

Yuuup my thoughts exactly lol

 

[Edgar Marton]

transmission/transfer case.... which fluid I have to fill in? I can buy Castrol Transmax in Hungary - but which one?

(1) Castrol Transmax Dexrion III H Multivihicle (automatic transmission)

(2) Transmax ATF DEXRON-VI MERCON LV Multivehicle

 

[Cabin 1]

2006 TJ Rubicon Manual.. yes this is a NP231J pared with my NSG370 and I was about to change my T-Case oil with Redline, however, I noticed the previous owner must have welded a Huge bolt in the fill plug location.

Assuming they must have stripped the OEM bolt..

I definitely don’t want to buy a new T-Case..

Am I doing more harm if I try to remove it and replace the fluid?

140K miles.

Thanks!
View attachment 547509

Looks to me that a bolt is welded to the plug. Due that hard to get them out at times. Did u try turning it to see

 

[MikekiM]

Looks to me that a bolt is welded to the plug. Due that hard to get them out at times. Did u try turning it to see

Did you read the rest of the thread?
It's almost a year old and the OP snapped the bolt off the plug.
Never updated with the result... New 241, another hack weld job or a repair.. unknown