1976 FJ40 Transfer case plug / leak fix

[76 FJEID]

I have a leak through this plug on my 1976 FJ40 transfer case and it appears there is a plug but, I cannot find or solve this one? I purchased the gasket rebuild kit but, it doesn't come with the plug.

 

[ijonesinsp]

This is a pretty common leak point. My kit didn't come with a new plug either; I just cleaned everything really good and added plenty of anaerobic sealant when I tapped it back in. It's been holding fine since.

 

[Mark Jennings]

That there be a ‘Welch Plug’…..it’s actually sorta’ kinda’ (and in some cases IS) a freeze plug.

To seat them correctly, take a 3/8 socket extension, place the square end in the middle of the plug, then give the other end a good rap with a hammer. Pushing in the center expands it into the aluminum transfer case.

You can buy these on e-bay, or at your friendly NAPA dealer. Measure twice, buy once, and use a metric scale. To get the old one out, you will need to drill (or punch) a hole in the old, pop it out with a screw driver….then use the above procedure to drive in a new one.

Good luck! Be Good, Be Safe.

 

[ijonesinsp]

I tapped mine out with the idler shaft if I remember correctly.

 

[Mark Jennings]

I tapped mine out with the idler shaft if I remember correctly.

I would only do that if the transfer case was on a bench. If you smack her to hard, you may end up pushing the shaft to far and losing the idler gear shims….ker-plop….into the sump they go

 

[ToyotaMatt]

I have a leak through this plug on my 1976 FJ40 transfer case and it appears there is a plug but, I cannot find or solve this one? I purchased the gasket rebuild kit but, it doesn't come with the plug.View attachment 3724777

This is the ticket


Surface prep is 9/10th of the law here

 

[ijonesinsp]

I would only do that if the transfer case was on a bench. If you smack her to hard, you may end up pushing the shaft to far and losing the idler gear shims….ker-plop….into the sump they go

It was definitely on the bench!

 

[Mark Jennings]

I’m not to sure about Matt’s suggestion of creams and goo’s for Welch Plugs. I think if you clean the hole out and make sure there are no nicks or grooves….maybe a little elbow grease and some 100 grit emery….you’ll get an adequate seal.

However, he is correct in the statement “surface prep is 9/10the law”!

 

[76 FJEID]

I have a leak through this plug on my 1976 FJ40 transfer case and it appears there is a plug but, I cannot find or solve this one? I purchased the gasket rebuild kit but, it doesn't come with the plug.View attachment 3724777

 

[76 FJEID]

Thanks guys! Awesome to have a forum of been there done that. Had never heard the term welsh plug…. I’ll update when I attempt the fix.

 

[76 FJEID]

Toyota Matt -Got the 1281` as suggested and cleaned it real well and sealed right up with no leaks the last month. Many thanks to all.

 

[ToyotaMatt]

I’m not to sure about Matt’s suggestion of creams and goo’s for Welch Plugs. I think if you clean the hole out and make sure there are no nicks or grooves….maybe a little elbow grease and some 100 grit emery….you’ll get an adequate seal.

However, he is correct in the statement “surface prep is 9/10the law”!

Thanks guys! Awesome to have a forum of been there done that. Had never heard the term welsh plug…. I’ll update when I attempt the fix.

on-topic here is TOYOTA 00295-00102 / 00295-00103 Oil Pan & Camshaft Housing Sealant , its BLACK in color

- 00295-00103 Black = ALL and ONLY Motor Oil / Coolant - Antifreeze Applications

- 00295-01281 RED FIPG = ALL and ONLY ATF , GEAR BOX AXLE Oil & Power Steering Fluid Applications


a good comparison here from post #1 is a Cylinder Head or Engine Block Freeze Plug , i have installed my fair share in both building my own land cruiser engines and also doing Freeze Plug repairs on Clients trucks and some cars at my own shop over the years , and before that at the dealership level

Surface prep no matter what even a NEW or Freshly hot tanked engine block or head is 9/10 th's of the Law here to be Krystal Klear !

the other 100% of that Law for me is ONLY ever use of 1 of the 2 OEM TOYOTA FIPG sealing products above ,

since being both in action correctly used and applied with a common small real natural black horse hair ACID brush ( you can get a 10pack of at home depot ) formally taught what the whole WET TACK DOWN philosophy really is and how it really works and also seeing from day 1 Both FIPG 's being used , applied and absolutely relied on from the new car 3/36 bumper to bumper engine and powertrain warranty time frame windows back in the late 1990's till right now 2024 as i plug away at GHOST ( 5/89 FJ62LG-PNEK ) . i used the black Engine FIPG -00295-00102 to install OEM TOYOTA Freeze Plugs in the Upper Air Intake Manifold Plenum while preforming my by my soon to be published paper print media glove box size spec . mini meme FSM manual ( 3-FE ENGINE SUPLIMENT EMISSION SYSTEM REMOVAL )

- i applied with the small silver metal ACID BRUSH more then 1 tube of 00295-01281 Orange FIPG when i did a 100% full on nuts and bolts restore , rebuild , refresh on my first ever rear full floating Axle on GHOST ....

- Summery : i have never yet had a single call back , leak or the hint of as seep when using in conjunction with the correct OEM TOYOTA Media gaskets and or O-Rings , or as a stand alone low cost ( guaranteed ) insurance policy.....


- NOTE : OEM BOTH TOYOTA FIPG 's discussed above are made by ASCO / AISIN JAPAN Ltd. fort TOYOTA .....


This is The Way ....

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