Transfer Case Plug Stripped - FJ62 (1 Viewer)

[Cbad Cruiser]

I am looking for thoughts and advice on using a time-sert to repair a stripped transfer case plug on my 1988 FJ62. Has anyone else done this repair and if so, what size did you use? Open to other ideas, but I think finding a donor transfer case is out of the cards for now. Appreciate anything the community can provide.

 

[3_puppies]

drain or fill?
fill, you could tap out to 1/2"? pipe

 

[cruisermatt]

NPT plug as a temporary fix until the next time you have the T-case apart, when it’s clean and on a workbench it’s pretty easy to weld the hole up, add material where Toyota deemed it unnecessary, re-tap and machine flat for a better-then-new repair.

 

[Cbad Cruiser]

drain or fill?
fill, you could tap out to 1/2"? pipe

It's the drain plug, sorry I meant to mention that. I read about tapping and using a NPT plug in another thread for the fill hole, but wasn't sure about how good of a fix it was for the drain. Time-Sert seemed interesting to me as an option, but I've never done that before.

 

[OSS]

For a temporary hillbilly shade tree mechanic band aid fix, (did I miss any other derogatory labels?) it could -maybe- be possible to replace the drain plug with a rubber expansion plug.
I've never done it and I'm not sure if the rubber would seal on the threads, but it is a poor man's possibility.
The expansion plug, once it's cranked in there tight could be left undisturbed and when it's time to drain the transfer case again, the oil could be sucked out through the fill hole (using a suction pump) instead of drained out the bottom.

Just an idea

 

[bentonrover]

I used this stuff and some teflon tape as a quick fix. That was 4 years ago. Not sure how bad yours is stripped out. I have another case and just been to lazy to swap out. Also you can find a larger bolt and tap into the case. I also did that with my 05 LX470 transmission pan. Rust belt remedies

 

[Spike Strip]

The Time-Sert works very well and is a permanent fix, but they are spendy for a one-time use. Size is listed in linked threads.

A possible alternative, if there are enough threads left, is to use one of the long, Allen-wrench plugs that may be able to engage some remaining threads. Long one - Part # 90341-18021

Various M18 x 1.5 plugs:

Stripped threads on transfer filler hole

The previous owner left us a nice little surprise that we discovered last night. When we got the 60, the PO said he just changed all the oil in the transfer, transmission, and diffs....so it was lower on our priority list of things to check. Mike had noticed some very minor weeping of oil around...

forum.ih8mud.com

Time-Sert vs HeliCoil

I wanted to post this for folks who were looking at HeliCoil to fix broken bolts, and might want to know about an alternative that I think is superior, though much more costly. Needing to fix several more broken bolts in the body of my '76 FJ40, I did a bunch of research on helicoil and came...

forum.ih8mud.com

BelMetric.com - Metric Fasteners & Hardware

Bel-Metric sells metric hardware & specialty automotive supplies nationwide. Visit our website to purchase metric fasteners, nuts, bolts, Time-Sert kits & more.

www.belmetric.com

Steel Taper Metric Drain Plug DIN 906

Bel-Metric sells metric hardware & specialty automotive supplies nationwide. Visit our website to purchase metric fasteners, nuts, bolts, Time-Sert kits & more.

www.belmetric.com

 

[3_puppies]

It's the drain plug, sorry I meant to mention that. I read about tapping and using a NPT plug in another thread for the fill hole, but wasn't sure about how good of a fix it was for the drain. Time-Sert seemed interesting to me as an option, but I've never done that before.

it will work in a drain also, as stated above, it should be done better when apart.

I did one on a semi truck oil pan 2 months ago and we just got the replacement oil pan in yesterday. the truck needed to run that night. it's been running the last 2 months, we'll end up changing the pan, most likely over the winter when its slower.
the oil pan is aluminium also.
used a brass plug with a hex head and some teflon tape

 

[Cbad Cruiser]

These are all super helpful. I appreciate the links and advice!

 

[lcwizard]

Last time I had this happen I went a from a 18mm to 20mm . I believe the t-case plug I used at that time was from a Mitsubishi Montero.
This happened ten years ago so forgive me if my details on the truck model are wrong but I'm still running that t-case without issue.
If you don't want to search for the plug, Belmetric sells a stainless version. Belmetric is one of those companies you should save in your
favorites regardless if you need them right now.

DP20X1.5AHSS - Stainless A2 Metric Drain Plug [DP20X1.5AHSS] - $5.53 : Bel-Metric, Metric Hardware, Metric Fasteners, Metric Bolts, Metric Nuts & Time-Sert Thread Repair

Bel-Metric DP20X1.5AHSS - Stainless A2 Metric Drain Plug [DP20X1.5AHSS] - M20X1.50, M20X1.5, M20 Metric Stainless Steel Drain Plug Diameter: M20 Fine Thread Pitch: 1.5 Head Diameter: 25mm Overall Length: 18mm Length Under Head: 14mm (3mm taper) Threading Length: 11mm Allen Head Drive Hex Key...

www.belmetric.com

 

[tmxmotorsports]

Last time I had this happen I went a from a 18mm to 20mm . I believe the t-case plug I used at that time was from a Mitsubishi Montero.
This happened ten years ago so forgive me if my details on the truck model are wrong but I'm still running that t-case without issue.
If you don't want to search for the plug, Belmetric sells a stainless version. Belmetric is one of those companies you should save in your
favorites regardless if you need them right now.

DP20X1.5AHSS - Stainless A2 Metric Drain Plug [DP20X1.5AHSS] - $5.53 : Bel-Metric, Metric Hardware, Metric Fasteners, Metric Bolts, Metric Nuts & Time-Sert Thread Repair

Bel-Metric DP20X1.5AHSS - Stainless A2 Metric Drain Plug [DP20X1.5AHSS] - M20X1.50, M20X1.5, M20 Metric Stainless Steel Drain Plug Diameter: M20 Fine Thread Pitch: 1.5 Head Diameter: 25mm Overall Length: 18mm Length Under Head: 14mm (3mm taper) Threading Length: 11mm Allen Head Drive Hex Key...

www.belmetric.com

Just saved to my bookmarks.