Just discovered that I have the same problem. Has anyone tried using a turbo socket (also known as a twist socket)? Supposedly it's designed for removing rounded bolts.
Transfer case Fill Plug Stripped???
- Thread starter Racehoss
- Start date
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Actually it's 17mm. I bought turbo socket from Sears (Craftsman). Tried it, and it doesn't work.
I had that happen to me too!! I drilled a hole on the middle of the plug, then use a square easy out to drive it out. It worked for me. And make sure you get new plugs and anti seize next time!!
Using this method, is there a risk of getting metal particles into the transfer case when you drill it?
Yeah, there's that chance. But if you get it out, all you have to do is spray some wd40 thru the fill hole until it comes out at the bottom. In addition, when you drill the hole, all the metal shavings should be driven out by the drill bit.
WD-40 will not flush all those filings, and drill bits never clear all the metal shavings. WD-40 will also change the viscosity of the gear oil, and may do Bad Things to the seals.
If the plug is frozen, you will break the easy out off. The inside of the Transfer case has all sorts of webbing, and those filings will catch in one or more of those holes.
If you don't have a welder, you can use lots of cleaner, sandpaper, and JB weld a piece of 3/4 x 1/8 steel strap. You can speed the process with a heat gun. The welded rod is still the best solution.
It's just not worth it to get steel filings in your transfer case. Do you really want run the risk of rebuilding it in then next 10,000 miles?
You're right about the shavings. I am planning on swapping my tc and I didn't care much about the longevity of the one that I had on right now. So you gotta weight your priorities. And wd40 is mostly fish oil too. So hey! Maybe you can gamble a little bit with a heat gun like other guys have said.
Good luck!
I used an air chisel.
Another option is to get a set of Spiral sockets. They have a left hand twist, so when you put it on the bolt, and twist to the left to remove the bolt, the spirals bite into the fill plug. Eventually the plug lets go. MUCH better than a (not so) EZ Out.