I'm trying to do my first transfer case fluid change in my 231 and the fill plug is stuck tight. Also, it doesn't look like all the other fill plugs I've seen as it isn't an Allen key like they usually seem to be or even the 30mm head that a lot of people have mentioned. I can't tell if it actually is an allen key plug and there's something stuck in it or if it's some odd kind of plug that a previous owner used. 19mm is the closest I could get and even that started to round out the edges. Does anyone know what this fill plug is or have ideas on how to get it off? The fluid was really nasty in the transmission and oil was in the engine too so I'd really like to get that stuff out of the transfer case since I'm guessing it's just as bad.
Transfer Case Fill Plug
- Thread starter Tiger98
- Start date
-
- Tags
- fill plug stuck transfer case
Looks like something the prior owner scrounged up somewhere. OR....it could be welded to the original plug. Either way, I'd heat it up as hot as you dare (considering aluminum doesn't handle heat like steel does). Then, spray cold water on it till it cools. Repeat a couple times. Then, heat up around the bolt and try to keep the heat off the bolt. Then, try to spin it off. Try different size 6 pt sockets till you find the tightest fit. Do not use 12 point sockets.
I would think a pipe wrench and a bit of heat from a torch would pull it right off.
(Note PIPE Wrench, NOT Adjustable Wrench. Adjustable would just round it off even further)
If that for some odd reason DOESN'T work, it's at least large enough you could weld a breaker bar to it and twist it out, then replace with something proper.
(Note PIPE Wrench, NOT Adjustable Wrench. Adjustable would just round it off even further)
If that for some odd reason DOESN'T work, it's at least large enough you could weld a breaker bar to it and twist it out, then replace with something proper.
Thanks, guys. Yeah, it seems like it may be welded to the original plug. I don't actually have a torch to heat it with so I might have to look into one. I'm a little nervous about the aluminum. No welder yet either unfortunately but I'd like to learn to do stick soon. I also thought about getting extractor sockets but of course I would need to replace the plug after as it would be destroyed. Does anyone know what the proper standard fill plug is or where to get it? I looked a number of places and they were out of stock.
I had a stripped drain plug when I got my Jeep. Previous owner. I heated and cooled the case and plug a couple times with an oxy/acetylene torch. A propane torch would have worked too just slower. Just have to be careful and don't let the flame sit in one place too long. I ground down a bolt till it fit snugly into the plug and MIG welded it in. Came out super easy. You need to get it hot enough to sizzle a little when you spray it down with cold water.
You can pick up a 14oz Propane tank and a Nozzle for $10-15 at Walmart.
In the camping section.
You're looking for this..
On the plus side, this little torch combo has been INVALUABLE with my TJ.
All the bolts that most people strip, or struggle with, just hit them with some heat and they come out easy as ever.
Don't be. Aluminum doesn't start to become structurally affected until around 300 degrees F.
Even then, It doesn't begin to melt until around 1,200F.
I highly doubt you'd even come close to hurting the TCase with a propane torch.
Just heating enough to break the bolt loose.
10-20 seconds max.
Where is that? I really would like to get the assuredly black fluid out asap. Also, is the speedo gear something that can be adjusted? My speedometer runs 10mph too fast due to the oversize tires.
I have not used this part but might be better than you have.....and might use this myself in the future!
https://www.ebay.com/itm/1249834826...pid=5337789113&customid=&toolid=10001&mkevt=1
https://www.ebay.com/itm/1249834826...pid=5337789113&customid=&toolid=10001&mkevt=1
Thanks! I'll have to check the walmart here and see if I can find one. During that 10-20 seconds do you just keep the torch moving around the bolt so as not to overheat any area?
Like a water spray bottle? I don't have a hose here. But yeah, it seems like something is welded into the original plug just like you did with your bolt, only I can't do anything with it since it's round. Other than maybe trying a pipe wrench on it.
Yeah, looks good! I appreciate it. I wish that was what was on there now. It would've made the fluid change easy like it was with the transmission yesterday
Yup a spray bottle of water will work fine. DEFINITELY heat it and cool it a few times. The case is aluminum and the bolt is steel. They are dissimilar metals so they will expand and contract at different rates. It's the expanding and contracting that will break the two apart in the threads. But, you need to heat it up as fast as possible and then cool it down as fast as possible. As you heat it, keep moving the torch around. I use oxy/acetylene and it's better because it gets so hot. But, you have to be even more careful with oxy/acetylene because it's so hot...it's fairly easy to quickly overhead the aluminum. It'll take a lot longer to overheat aluminum with a normal propane torch. Just heat it up by constantly moving the torch. Also, draining the fluid will make it easier to heat up because the fluid will absorb some heat...but be aware, once it's drained if you can't get the fill plug out, the only option you have is to fill via the speedometer connection and you'll have to refill by volume.
It needs a few heat/cool cycles before it's ready to loosen.
Okay, I may try the torch method then. Where is the speedometer connection in case I'm unable to get the fill plug off?
MountaineerTom
LJ Enthusiast, Retired USAF Weapons Loader
Supporting Member
Ride of the Month Winner
Circled in red. The 2nd pic is of it out of the tail housing. The gear is replaceable with one with the right number of teeth for your tire size.
Oh, cool! That's really helpful, thank you. I need to get a new gear set and it looks like it's high enough to get most of the 2 quarts atf+4 I bought into the case
I would knock a 6 point socket that fits tight on all the way and remove. If that didn't work I'd weld a big nut on or use a pipe wrench
Yeah, looks like I will have to try the pipe wrench first since I don't have a welder or 19mm 6 point socket
What about a grinder? Grind two opposite sides flat so a big crescent wrench or pipe wrench can get a better bite
That's also on my list of tools to get
I got this thing in August and have been teaching myself how to fix and maintain it and acquiring the necessary tools along the way. That's a good idea thoughSimilar threads
