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Stuck transfer case filler plug
Posted: Mon Mar 19, 2018 1:10 pm
by niclemaitre
Hi there
My filler plug on the transfer case is stuck solidly. After stripping it with a socket
, I've tried the vice grips, the bigger vice grips, the Knipex pliers, a smaller cheap Chinesium socket hammered on and nothing. There's not really room for the bobbejaan in there.
I'm left with two choices:
Break an easy-out off in it
Weld on a nut.
I'm worried that since the transfer case body is aluminium, welding a nut to the filler plug (which seems to be steel, since it's magnetic) might damage the case body. I only have an arc/stick/SMAW welder so its going to be interesting. Any advice, cautionary tales will be gratefully accepted.
Cheers
Nic
Re: Stuck transfer case filler plug
Posted: Mon Mar 19, 2018 2:07 pm
by Mars
Hi Nick
As long as you do not draw an arc on the aluminium it should be fine. Fortunately the welding will not stick to the aluminium. I once tried to help a guy who had managed to weld a broken bolt very nicely to the cast iron engine block. That was a bit of fun. I have welded out broken studs/nuts from aluminium cylinder heads and engine casings without issue before using an arc welder. The process of welding a nut onto the plug has the added benefit of really making the plug very hot which causes it to expand. Once cooled off you might actually find that the plug comes out much easier.
Make sure that you disconnect the alternator (all the wires) before you start welding (and maybe even the earth clamp of the battery for good measure).
Re: Stuck transfer case filler plug
Posted: Mon Mar 19, 2018 2:32 pm
by ismail
have you tried hitting a smaller hex socket on it? rather than the multipoint socket.
Re: Stuck transfer case filler plug
Posted: Mon Mar 19, 2018 2:42 pm
by Mud Dog
Mars wrote: ↑Mon Mar 19, 2018 2:07 pm
Hi Nick
As long as you do not draw an arc on the aluminium it should be fine. Fortunately the welding will not stick to the aluminium. I once tried to help a guy who had managed to weld a broken bolt very nicely to the cast iron engine block. That was a bit of fun. I have welded out broken studs/nuts from aluminium cylinder heads and engine casings without issue before using an arc welder. The process of welding a nut onto the plug has the added benefit of really making the plug very hot which causes it to expand. Once cooled off you might actually find that the plug comes out much easier.
Make sure that you disconnect the alternator (all the wires) before you start welding (and maybe even the earth clamp of the battery for good measure).
+1
If you're going to weld under there, button your collar right up (not funny if splatter or slag gets into your shirt ... ask me ...
) and use long welding gloves if you have.
Re: Stuck transfer case filler plug
Posted: Mon Mar 19, 2018 2:46 pm
by niclemaitre
Thanks guys.
I'll see if I can find a hex socket, then try the welder.
I know all about getting slag into my clothes. Such fun. I'll make a scarf from a cotton rag.
Re: Stuck transfer case filler plug
Posted: Mon Mar 19, 2018 4:30 pm
by ismail
get an impact socket if you can the points seem to be sharper
Re: Stuck transfer case filler plug
Posted: Mon Mar 19, 2018 7:16 pm
by The Legend
Sometime that nut get loosen the moment you put heat on it.
Re: Stuck transfer case filler plug
Posted: Mon Mar 19, 2018 9:43 pm
by pietpetoors
When you loosen a metal filler plug in alu, always tap it with a hammer before you put on the socket and try to loosen it. It relieves the stress.
As for now after stuffing it up, my favorite way of doing it is to use a small chissel and hit it on the side of the head, so that you turn it with the chissel.
Re: Stuck transfer case filler plug
Posted: Tue Mar 20, 2018 12:18 am
by Mud Dog
The cold chisel story works, especially on bigger diameter bolts and nuts but personally I would avoid too much hammering around the aluminium casing for fear of cracking it. I would still go the welding route, but carefully. Find a big nut that fits over the damaged plug end and weld it on the inside of the nut.
Re: Stuck transfer case filler plug
Posted: Tue Mar 20, 2018 8:13 am
by niclemaitre
Got it free eventually.
Tried the 6 point socket (the el-cheapo sockets from Midas are surprisingly durable), didn't work.
Tried with a cold chisel and a hammer to turn it, but that didn't work and I was getting close to damaging the sealing face on the housing.
Welded on an M20 nut, then hammered a slightly smaller Imperial socket onto the nut (something like a 29ish equivalent), and broke it free with a powerbar.
Drained the diff, refilled it, with lovely new oil and then put in the new plug, with lots of copperslip on the threads, to the correct torque.
Re: Stuck transfer case filler plug
Posted: Tue Mar 20, 2018 9:11 am
by ismail
happy days, glad you came right.
Re: Stuck transfer case filler plug
Posted: Tue Mar 20, 2018 9:34 am
by Mars
Mooi man!
Re: Stuck transfer case filler plug
Posted: Tue Mar 20, 2018 9:42 am
by Mud Dog
Re: Stuck transfer case filler plug
Posted: Tue Mar 20, 2018 10:00 am
by niclemaitre
ismail wrote: ↑Tue Mar 20, 2018 9:11 am
happy days, glad you came right.
Me too, you have no idea, how glad I am. I had visions of having to strip the transfer case, which according to the manual requires pulling the entire transmission.
