stripped out the drain plug in the transfer case

daddyizzle

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stripped out the drain plug in the transfer case

« on: July 02, 2007, 06:31:28 PM »

I was pulling off the transfer case on a donor vehicle. It's dry so I'll see if it's quiet. I thought I would drain the fluid first and when I went to remove the plug, I noticed that somebody else had stripped it out a little. I stuck my allen key in all the way and even tapped it in with a small hammer to make sure I was getting a good bite. When I tried to turn it, nothing. I finally got the wrench to move and it just wallowed out the hole. There's not enough meat to grab it with vice grips and I'm not sure I want to drill it out and use an extractor. What do I do now?

Can I replace the bad one with some bolt from an autoparts store once I do get it out. . I never did like the allen bolts. Someone torqued the piss out of this one!!

I also broke one of the 4 identical mounting bolts off. I guess I drill it?

-Adam

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olija

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Re: stripped out the drain plug in the transfer case

« Reply #1 on: July 02, 2007, 10:38:20 PM »

What I did was get someone to either

a) heat up the transfer case with a torch, because it is aluminum and the plug is steel so they expand at different rates, then see if you can wedge your allen key in there again and get it out

if that doesn't work

b) weld a bolt or nut into/onto the plug

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mrfuelish

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you must have a perception problem.

Re: stripped out the drain plug in the transfer case

« Reply #2 on: July 02, 2007, 11:05:29 PM »

It's a pipe thread so you could buy an american pipe tap and an americam pipe plug and try to tap it just a little deeper, then drill and tap the new plug with say an 1/8" pipe and put the larger plug back in with jb weld and call it good, get some freon or one of those computor cleaner cans and hit the old plug real good with it and see if you can shrink it out of the hole, or your going to have to weld a large bolt to it, is this a sammie?

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daddyizzle

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Re: stripped out the drain plug in the transfer case

« Reply #3 on: July 03, 2007, 05:45:06 AM »

Yes it's a sammy. and it's off the vehicle. If I drill it enough to get a bit an extractor in it and hit it with the freon, do you think that will get it out?

-Adam

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95sidekick

Re: stripped out the drain plug in the transfer case

« Reply #4 on: July 03, 2007, 09:45:50 AM »

if you are able to get a hold of an air hammer put a chisel bit in and hit the one side a few times it usually brakes it loose and you can get it out by hand

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mrfuelish

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you must have a perception problem.

Re: stripped out the drain plug in the transfer case

« Reply #5 on: July 03, 2007, 04:40:12 PM »

if it is out of the rig buy a bolt and have it welded to the plug and let it cool over night it will come right out.

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daddyizzle

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Re: stripped out the drain plug in the transfer case

« Reply #6 on: July 03, 2007, 07:42:14 PM »

Thanks for all the suggestions.

I ended up getting it out by using some of that office duster stuff in the can. I think it helped. I just kept shaking it and blowing the air on the area around the plug and over the plug. I took a real large flat head screw driver (one of the old bad-ass ones) with a pair of vice grips and I put all my downward force on it while I smacked the vice grips. I guess I got lucky. I couldn't go anywhere because my wife had the working vehicle at work so it was worth a shot and it payed off.

One thing I found out was that the plugs aren't allen

I think a 3 /8 ratchet will go right in.

They were already wiped out though and full of gunk so I couldn't tell until it was too late.

I tried drilling out the broken bolt where the 4 bolts hold the transfer case to the mount on top of the transfer case and I ended up breaking the bit in it.

I tried several bits and even a cobalt bit and couldn't drill into the hole.

. My wife came home and I dropped it off at a 4x4 shop in town and they were supposed to get it done by 5:30. I went by to pick it up at 5:15 and they were closed. I was pissed (sort of)

I hope they can drill it out. I'm thinking they may have to stick it on the mill and use an end-mill or something (like I really know what I'm talking about)

I hope they go easy because we're kind of tight for the next month. I think I used too many of those smileys. I need to learn to weld anyways.

-Adam

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museboy07

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Re: stripped out the drain plug in the transfer case

« Reply #7 on: July 03, 2007, 07:50:29 PM »

Quote from: daddyizzle on July 03, 2007, 07:42:14 PM

One thing I found out was that the plugs aren't allen I think a 3 /8 ratchet will go right in. They were already wiped out though and full of gunk so I couldn't tell until it was too late.

I was gonna post earlier when you first made this thread and mention that it was a 3/8 racthet size...but i was in a hurry...sorry

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daddyizzle

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Re: stripped out the drain plug in the transfer case

« Reply #8 on: July 03, 2007, 08:07:39 PM »

That's o.k. They look pretty wiped out. When I get it back, I'm going to take a dremmel to them to take the burs off and see if the 3/8 will fit anymore. If not, I'll just replace both. There was so much oil running off the engine that it soaked the whole under side of the donor vehicle and there was just so much gunk build up. It looked like an allen until I got it off and upside down and cleaned up. Know I know.

-Adam

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If all criminals were behind bars, there would be no one left to patrol the streets.

86 Samurai Tin-Top stock with a Harley 44 sidedraft carb

mrfuelish

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you must have a perception problem.

Re: stripped out the drain plug in the transfer case

« Reply #9 on: July 03, 2007, 10:03:24 PM »

When I would break off easy outs and drill bits I would take a center punch and try to break them up in the hole or I would have to take it to a place that could elox (spell check) the part out or next would be a laser which might be easyer to find, for repairing the hole I use time serts, they are alot better than the other thread repair stuff you buy at napa, the tool cost about 100.00 bucks and the inserts were over a buck apiece way back when but it makes the case stonger than stock or anything that you use them in, I can even fix a stripped out spark plug hole with out taking the head off, alot of motorcycle shops use them so you might be better off going to one of them than a 4x shop.

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1987,1988,1988,1990 samurai's, 1953 m38a1, 1996 x-90,blue.1996 x-90 red.1994 2 door tracker. only Dead Fish go with the flow. No Hairy Nosed Wombats were ran over on the trail today. My ZUK is Xenophobic.