Fill Plug Removal

[malcb]

Came up with a problem last night.

Fill plug for the transfer case has presented a problem for someone in the past and is quite messed up. Groved in the base where a chisel has been applied, rounded head etc.

I did hammer a 6 sided socket on and got quite a bit of force on the plug, also tried an impact tool but in the end the socket spun.

Anyone got some ideas. How much heat can I apply, if any?

Could I get way with welding flat bar onto the plug?

Don't really want to refill through the breather fitting.

 

[craptabulous]

try hitting the plug with a hammer first . it loosens it up , just hit it straight on .

if its really bad weld a nut onto it and take it off with a wrench .

 

[Southeast Overland]

try hitting the plug with a hammer first . it loosens it up , just hit it straight on .

if its really bad weld a nut onto it and take it off with a wrench .

What he said.

Many people will drain first then see they can't get the fill plug out.

 

[malcb]

What he said.

Many people will drain first then see they can't get the fill plug out.

I did that , actually would still have even if I knew about the filler plug, had to see the oil as I didn't know what was in there, turns out it's quite clean, also wanted to see inside the hand brake - and found a loose output nut .

Using the vent and a measured fill should be an option but I don't like that option much.

 

[Southeast Overland]

Try to weld a nut onto the rounded off fill plug if you have a welder.

 

[Pete]

Came up with a problem last night.

Fill plug for the transfer case has presented a problem for someone in the past and is quite messed up. Groved in the base where a chisel has been applied, rounded head etc.

I did hammer a 6 sided socket on and got quite a bit of force on the plug, also tried an impact tool but in the end the socket spun.

Anyone got some ideas. How much heat can I apply, if any?

Could I get way with welding flat bar onto the plug?

Don't really want to refill through the breather fitting.

Welding a nut on it like others suggested will probably work but an easier way would be to try a small pipe wrench with good sharp teeth. Since your fill plug is trashed anyway or will be for sure if you weld a nut on it, no damage will be done with a pipe wrench. Use a cheater pipe on the pipe wrench and you should be able to break it loose if there's enough of the plug left to get a bite on. Oh, and make sure you've got the wrench in the right direction!

Pete

 

[IDave]

If it can take a welding torch, it would take a Propane or Mapp gas torch. I'd try that with some Kroil, PB Blaster, or whatever you have over there across the pond and Pete's pipe wrench first.

 

[malcb]

Welding a nut on it like others suggested will probably work but an easier way would be to try a small pipe wrench with good sharp teeth. Since your fill plug is trashed anyway or will be for sure if you weld a nut on it, no damage will be done with a pipe wrench. Use a cheater pipe on the pipe wrench and you should be able to break it loose if there's enough of the plug left to get a bite on. Oh, and make sure you've got the wrench in the right direction!

Pete

Done.

The pipe wrench was an easy option so I gave it a try, my wrench is a bit large and it rounded the nut.

Plan B was weld a nut on so I grabbed an M24, hacksawed it in half (because I need the exercise), cleaned the end of the plug and it knocked over the rounded stub perfectly. Good bit of rod on it, some more just to add a bit of heat, 30mm spanner and got a boot on it ready for a fight. Hardly has to push, seemed hand tight. I think the heat did most of it.

EDIT: Reason for the rush - I lose the use of a really nice workshop and the end of May.

EDIT2: Trash the plug - it's a heavy duty M24 version now.