Hello Zuki Members,
                              I have a 86 JX Sami, It feels as though the shifter for the transfer case is a bit sloppy and has popped out of 4X4 a few times while charging some hills on soem bumpy roads. Is there something that I should be looking at replacing ? Also I noticed a Oil leak coming from the Seal I think where the shaft comes out of the T case into the Transmission, I know I have to take the T case out to get to the flang nut off but since Im going to have the T case out is there some other maintance stuff that I should do to it? Also my fluid Check plug on the damn thing I dont think has been ever off, I took my 3/8 drive breaker bar and felt it start to strip so i stopped, any ideas on how I can get the Plug out? Any advice would be greatly appreciated.

I took my 3/8 drive breaker bar and felt it start to strip so i stopped, any ideas on how I can get the Plug out? Any advice would be greatly appreciated.

For starters you could try using the correct tool - the recess is actually a 10mm square, and your 3/8" bar measures around 9.5mm - if it does strip you can try welding a bolt into the recess - that gives you a better surface to grip, and the heat will help loosen the plug.

For the sloppy shifter, the shifter sheet is probably gone.

I would spray some PB Blaster around the edges of the plug. It should help loosen the threads up.

Any plug that is tight, I have good luck heating only the plug with a torch sometimes even to red,then spray with penetrating oil. When it cools off a bit, try to turn with the wrench, it will surprise you how loose it will be. Good luck!

Frodem said:

"For the sloppy shifter, the shifter sheet is probably gone."

Other signs of failure includes the inability to shift at all.

The best solution can be found here -
http://www.zuksoffroad.com/ZOR-T-Bra-solid-brass-t-case-shifter-sheet-for-Suzuki-Samurai_p_71.htm

At 18 bucks, it is a steal!  More than a few unknowing folks have had their transfer cases "rebuilt" as a result of a failure by a 10-dollar piece of plastic that can be replaced with two largish flat-blade screwdrivers and a 10mm wrench in as little as 20 minutes.

I hope that this helps!