t-case problems...

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BigSur

BigSur

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OK, like a rookie i drained the t-case before i could remove the filler plug. Well the PO completely stripped the plug and now i can't get it off and the t-case is empty. Where else can i fill up/ Can i fill up into the speedo hole next to the output shaft? HELP!!! I am leaving for the roundup on Friday i can't go if my t-case is empty.

Thanks,

Jason
 
Can you drill a small hole in the plug, and use an easy out?
 
Get your biggest pair of vise grips and get them so tight you almost have to use another wrench to lock them down on the fill plug. Work on getting the fill plug out. I don't know of another way to fill it that would work.
 
I tried everything in my power to get that stupid filler plug out but to no luck. Can i fill up the t-case through the speedo cable inlet hole?
 
did you try hammer and chisel? make an intendation on the side of the plug, then chisel diagonally counterclockwise.
 
Heat is your friend
Step 1 :get a pair of vice grips on the plug
Step 2: fire up torch
Step3: place flame on case around fill plug
(Science: Aluminium expands faster than steel the hole gets bigger plug stays the same)
Step 4: wack vice grip with BFH


If all this fails fill through vent hole in top of case

Dynosoar
 
Do you have a welder? If so weld a good sized nut to the plug. Weld on the inside of the nut so it will fuse to the plug. Let it cool and then use a wrench to unscrew the plug. This technique also works for removing broken studs, etc. Good luck.
 
Last straw. If you are unable to get the plug out as described above. magnatize your drill bit or oil it and use a vacuum. Drill the center of the plug out to approximatily 1/2" or the fitting opening "start with a small bit and work up" refill the transfer case and then insert a plug into the new filler hole. tap it, stuff a rubber cork into it? Go to round up and have fun. "keep an eye on the filler plug" couple quarts of gear oil would not be a bad idea.
Come home, re-group and then get back after it.

Jim
 
Update!!

Ok, i can't get the plug off at all...so i removed the speedo cable and i slowly poured in the correct amount of fluid into that. Just to make sure it got in there correctly i removed the drain plug and BAM! Fluid was flying out....so needless to say i have to fill up twice. But atleast i know now i can fill it up there.

Thanks guys for your help and advice...when i get back from the round-up i will tackle that plug.

jason
 
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