Mild to huge rant

That will teach you to do your PM.....
 
BTDT

Best bet is to just weld a nut onto the end of the fill plug, then wrench off of that.
 
They make oversized (OS) and a little more than oversize (OS2) drain plugs for sheet metal oil pans...would that work on a t-case? If its an aluminum case, I think there's a good chance it would. I picked mine up at Advance or AutoZone.
 
I'm gonna try and weld a nut on tomorrow and see what happens. I just didn't realize the hex hole was rounded out. I don't believe Ive ever felt so retarded in my life sitting at the house with one jeep and an empty tcase with no way to fill it. If this doesn't work I have no freaging clue what to do. Am I going to have probs with that alum case welding a nut on?
 
willness33 said:
Depends on the process you plan on using.
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Mac5005 said:
I would think the fill plug is steel, not aluminum, so you should be fine.
If the plug is aluminum, either TIG, or alum wire mig it.
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Yeah, what the hell was I thinking? I'll bet the plug was/is steel, threaded into the alum case. There's no way you can weld a steel nut to the alum case to serve as threads for the plug. I think the only option other than an oversized plug is to tap the hole for a bigger plug. That's quite the fubar.
 
The worst-case-scenerio solution would be to leave it in place and give up on that plug - and find a nearby locatio nand drill a whole new hole and tap that badboy. Not ideal by any means but will get the problem solved.
 
raleighjeepguy said:
Draining your tcase and then realizing the PO stripped out the filler plug! :fuck-you: :shaking: I really wanna kick myself in the a$$ for this one!
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At least its just the tcase filler plug thats stripped and not that the PO put 5th gear on backwards in your tranny resulting in your DD truck not being usable for over 6 months cause your to broke to afford to fix it :handed:
 
Actually this reminds me of something...
where can you find differential drain plugs that use a hex (allan) or square (3/8" drive) insert to remove them? E,g, plug is female so when the corners get rounded off on rocks you can still remove it? Need one for Yotas.
 
RatLabGuy said:
Actually this reminds me of something...
where can you find differential drain plugs that use a hex (allan) or square (3/8" drive) insert to remove them? E,g, plug is female so when the corners get rounded off on rocks you can still remove it? Need one for Yotas.
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You mean like the ones that are shown with the large diff armor?
http://www.trail-gear.com/trail-armor.html
 
raleighjeepguy said:
I don't believe Ive ever felt so retarded in my life....
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I don't think I'd feel as retarded as the PO that stripped it. HOW THE HELL to you strip the fill plug? You don't tighten them that much!

As for fixing, yes that fill plug will be steel. Find a bolt that the head fits in the hole. Stick the head in the hole and weld around the shaft of the bolt of the bolt. then thread a couple nuts on the bolt and extract the fill plug by wrenching on the first nut you put on the bolt.
 
mbalbritton said:
I don't think I'd feel as retarded as the PO that stripped it. HOW THE HELL to you strip the fill plug? You don't tighten them that much!
As for fixing, yes that fill plug will be steel. Find a bolt that the head fits in the hole. Stick the head in the hole and weld around the shaft of the bolt of the bolt. then thread a couple nuts on the bolt and extract the fill plug by wrenching on the first nut you put on the bolt.
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Ive actually done this minus the weld...
 
Use a hammer and chisel to get it out. Maybe heat the area first with propane and hit it with some pb blast.
 
If the fill plug is stripped and not the threads, then if you get an EZ-Out in it. I would think that would work. You might have to drill on it a little to make a smaller hole for the exstractor to fit.
 
blazeproc said:
If the fill plug is stripped and not the threads, then if you get an EZ-Out in it. I would think that would work. You might have to drill on it a little to make a smaller hole for the exstractor to fit.
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Be real careful with this.
Did this on a buddies back in va, ended up with a hole in the fill plug, and still not able to get it out.
We ended up trashing the plug, then rethreading the hole because all the threads were trashed. Apparently the reason it was rounded out, was it had been crossthreaded.

That said, other than the pita, dropping the tcase and splitting it if you go that route isn't that big a hassle. and the weather is nice out for it.

Good luck.
 
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