Newbie here! transmission and tcase fill plugs seized and rounded

[bridges]

Hey guys,

I bought a poorly running V8 converted FJ60 about 2 months ago and just got it back on the road (replaced the engine) and have gone through the first tank of gas.

I'm noticing a slight (nickel size spot) leak from the tcase and a whining noise similar to a rear differential going bad. I've stopped driving it until I can make sure I'm not running it dry but I have a problem in that the fill plug is seized and rounded off on both the tranny and transfer case.

Does anyone have a suggestion for removing these? I'd rather not have to drill it out and retap the threads if at all possible.

Noise is only when moving AND under power, gets very faint to non existent when coasting.

Thanks guys, the tech info here has made for a ton of learning already!

 

[cruiser_guy]

Drill out a hole for an extractor and remove the plugs. The hole need not be very big, just large enough for a large extractor to catch.

 

[hodag]

Since it is f***ked already, and if an easy out or vise-grip wont work, weld something to it that will allow you to back it out.

I had the same problem on my FJ55, I just welded an old bolt to it. It was long enough to get a cheater pipe on to back it out, then take off the cheater, and finish backing it out by hand.

Try the easy-out first, they usually work pretty well.

Hodag

 

[Dynosoar]

Hammer and chisel is the way to go. A couple of good whacks with a BFH and a sharp chisel and those suckers will come right off.

Dynosoar

 

[mrsvle]

You can also take it to an oil change shop and ask them to drain and refill your tranny and transfer case. They should be able to get the plugs off in a second with their air wrenches. Bring replacement plugs with you and have them put on the new ones, but tell them to be careful since it was probably one of these outfits that fawked up the plugs in the first place. It will cost you some for the new gear oil, but it probably needs to be changed anyway.

Also, there may be nothing wrong with the tranny or transfer case, the tranny is fairly loud and whiny on these old FJs.

And, you may find the tranny is way overfilled while the transfer case is low. When a seal in there goes bad, gear oil gets pumped from the transfer to the tranny. Some, including myself, have rigged up nipples and a line attached to the two fill plugs to drain the oil back down from the tranny to the transfer. SOR has such an item for sale if you don't want to rig it up yourself or if you just want to see what it looks like.

HTH

Matt

 

[bridges]

Thanks!

Thanks for the input -

Reading about the seal problems between the transfer case and transmission is what got me concerned with the noise initially.

I'm going to try the 'use force' methodology tomorrow starting with a pipe wrench and cheater tube.

If that doesn't work, I'll let the guys at the local oil change place take a gander.

I bought a welder to uh... build a fence at the house... (excuse worked with the better half!) but it hasn't been used yet. I would hate for the first time I try it out to be under my new daily driver...

I'll post the outcome when I get this resolved.

 

[brett76]

and once it runs dry it will always whine.
i drove mine for six hundred miles before i got around to changing my t-case fluid. only to find there was none. i didnt know the seal leaked because it was empty. added fluid seal leaked changed seal. the only problem with it now is there is a little play in the ouput bearing. no problems for ten thousand miles now.

thats a testament to tough. at least 600 miles dry. no telling how far before i picked it up

 

[Pluton]

One COULD use a Dremel-type tool to cut a slot across the plug, then a BF screwdriver to remove, and of course replace w/ new plugs.

 

[Cruzerman]

I suggest that when you do get it out, that you replace it with a plug that uses a 10mm hex wrench. These type of plugs are available through Toyota or many of the popular parts houses. Only a few bucks each. You'll never have that problem again.

________________________
Cruzerman
'85 FJ60
'78 FJ40