[OlympiaFJ60]

Finally got around to writing this up. Here is what I did to fix my stripped out fill plug on the transfer-case. Will work for the drain plug too, but case has to be apart. I used the timesert drain plug repair kit. It is a little pricey, but I plan on doing them on all my rebuilds. It is like a helicoil or other threaded repair insert but is solid and locks itself in place.

I'm sure for the one time thing, taking it to a good aluminum welder like mentioned in some threads would be cheaper, but I like having the solid steel threads in there.

You can see the details here Timesert drain plug repair

[nicholastheczar]

My Tcase fill plug is stripped out also, but $300 for the kit is too much in my mind. Now $30 on the other hand is doable. Did you do the $300 timesert or $30 Olympia kit?

[OlympiaFJ60]

Originally Posted by nicholastheczar

My Tcase fill plug is stripped out also, but $300 for the kit is too much in my mind. Now $30 on the other hand is doable. Did you do the $300 timesert or $30 Olympia kit?

I did by the kit, but I can do them for people if they send me the case half, for about $30. I plan on doing this on the rebuilds I do, so the $300 cost will get spread out over several cases. I also figured I could do them for others and recover some of the cost.

[agent orange]

So what exactly did you get for 300 bucks? A bunch of stepped helicoils?

[OlympiaFJ60]

Here is what you get, drill bit, tap w/alignment collar, inserts (5), counter bore tool, insert tool.

http://www.timesert.com/html/drainplug.html

Probably not worth it to most, but it is to me. I'm sure I could have found it for less if I wanted to search, but my local fastener vendor was able to get it in two days.