Frozen, head now stripped, Transfer case drain plug

[meatloaf]

As the title says, the TC drain plug is frozen and i rounded the head trying to loosen it up. can i heat it up without damage? should I drain the oil after heating it up? or, IS THERE ANOTHER WAY TO LOOSEN & REMOVE THE PLUG???

Thanks in Advance,
ML

 

[Tapage]

drilled and use big extractor . ?

 

[klinetime574]

Weld another nut on the outside of it. Heat it up. Drain the fluid after. Should be fine

 

[LB LandCruiser]

find a socket that just barely wont fit. lightly hammer it on until it sits flush with the t/case. it lightly doesn't work. hit it harder, just don't damage the t/case. use your ratchet to get it undone. worked for me

 

[TRAIL TAILOR]

X2 on welding a nut to the plug. If you don't have a welder... Get a pair of vise grips and a mapp gas/benzo torch and heat it up to remove. Then replace with new.. Good luck.

 

[tag3]

Used a big pair of vice grips on mine, then replaced with magnetic one.

 

[Kurtis]

The best is to just use an impact to start but If I ever freeze them I just knock them a couple times with an air chisel and they come right out.

 

[Spike Strip]

Be VERY gentle... Those ALUMINUM threads strip easily. Best to use a couple of heat cycles and maybe some PB Blaster. You strip the threads, you'll curse the Gods.

And I don't understand your OP if you're asking about whether or not to drain the oil and remove the drain plug in the same sentence ?

 

[tmonty]

Option 1-Weld a hex nut onto the bottom of the existing plug by welding the inside of the hole solid!! The heat from welding will help loosen the plug. Then put a wrench on the hex nut & spin off. Replace with a new drain plug. The oil will be fine, but if you were taking off the drain plug, you were probably replacing it anyway!!!

Option 2-Get a set of vise grips on the drain plug (side ways) & adjust it as tight as you can!!!! Get a propane tank or mapp gas (is hotter) and heat up the plug in the center of the plug. Heat 1-2 minutes, try to turn vise grips counterclockwise, if it doesn't come lose, heat another 1-2 minutes, should come lose then!! DO NOT put heat on the transfer case housing!!!! BE VERY CAREFUL NOT TO FORCE IT OFF OR YOU"LL STRIP THE TRANSFER CASE THREADS!!!!!!! YOU WILL HATE LIFE IF THIS HAPPENS!!!

GOOD LUCK!!!!

 

[meatloaf]

And I don't understand your OP if you're asking about whether or not to drain the oil and remove the drain plug in the same sentence ?

Spike,

good point. my problem is not with the drain plug but rather the fill plug. My concern was with the heating up of the oil. Thanks for pointing this out.

ML

 

[60Works]

My .02.

The oil will protect your gears and bearings from uneven hot spots. Leave it.

If you don't have a welder to weld a nut on the plug, you might try filing or grinding new flats on the rounded plug. Either redressing all six and trying another smaller socket or just two and use a Vise Grip. A cut off wheel might work; being careful of the aluminum case. Use a new set of Vise Grips with sharp teeth and grab your new flats axially rather than with the Vise Grips next to the case. Grip it as tight as humanly possible, maybe even using pliers to close the Vise Grips. Then use a large cresent to turn the Vise Grips. Sometimes I use valve grinding compound to add more gritty friction. (It works great on stripped Phillips head screws.)

A large easy-out might work too but if you drill through the plug it will leave shavings in the case. Plus you might be fighting dripping gear oil once you drill through the plug depending on your fill level and parking angle.

Mild heat is your friend. Mild. Propane several inches away is more than hot enough. Warm like an oven not a cutting torch. Focus on the aluminum case. I realize this is different from other advice. The aluminum case will expand (and contract) at a quicker rate than the steel plug so you will want to catch it as it warms rather than as it cools. It will take a while because you will be heating the gear oil too. Putting an ice cube on the plug while heating the case might help.

Good luck.

 

[tmonty]

I think you are right about heating the aluminum case rather than the plug!!! But if he is asking how to do this & this is his first time, he may end up cracking the case with to much heat!!!!

Also, with the oil in there as a heat sink, it'll have to get everything pretty warm to heat it up enough!! May cause damage to a seal!!!!

I'm pretty sure he won't care about ruining the plug!!! It needs replaced anyway!!!!

That was a good suggestion about reshaping the plug if he can get to it with some type of tool!!!

I hope he figures it out!!!!!

I gave him the 2 that has worked for me!!!

 

[rusty_tlc]

I would avoid using an easy out at all cost, once you break them off the hardened steel is almost impossible to deal with.

 

[darthvincor]

Used a big pair of vice grips on mine, then replaced with magnetic one.

I used this method too. Vice grip on the plug, nice and tight, and then a rubber hammer on the vice grip.