Well I did the transfer case last summer and I was very careful to never over tighten it. I usually do it every 25 or 30k. I'm not sure if the dealer touched it when installing new drive shafts but here we are and its stuck in there. Seems unlikely they would have to touch the transfer case so I guess it had to be me? Tried PB Blaster and used the #10 and a 3/8 extension and ruined the hex inside so that the #10 is useless now. I may be able to get it to bite once more but I figured I had better stop for today and first order a new plug.

1. Is this a dealer only item or does anyone have a part number?
2. Suggestions on how to handle this since the plug is alluvium. Easy out? Dremel Tool to make a slot then a screw driver? I have a heat gun so maybe try that with the last amount of bite I can get? Weld a bolt into it if that's even possible?

My concern is the aluminum and the fact that I had a pretty good bite on it and a 3/8 extension and I stripped the head. I'll continue to PB blast it in the meantime everyday and let it soak. Funny part was right before it I easily got both bank 2 02 sensors replaced in under 45 min. I thought that was going to be the nightmare. Funny how this wrenching always works isn't it. Someone with more brains then me would have definitely noticed it wasn't spinning but it was stripping. Let my guard down for one second.

 

I can't say for sure, but I think I'd chisel a small notch in it and hammer away with a chisel to get it spinning, then I'd look and see what it takes to replace it. I'm not very patient though.

 

It's funny you mention that because I think the chisel method will be the best method to work. PB blaster and Kroil and hit it downward at the 9:00 spot to see if it comes down.

Is this a dealer only purchase replacement part?

 

Wow.. try the chisel.. maybe drill to facilitate extractor bit being Al, heat will expand it and maybe it will cool down and break loose... anyway here is the OEM Info I believe is accurate for 2008 JK
5097712AB Plug, Oil Drain Chrysler List Price: $9.10

 

This looks like it could be for a differential and not transfer case but Im not sure. Here is what the picture looks like on Rock and many of the other mopar sites talk about it being for diffs also.

https://www.rockauto.com/en/moreinfo...93258&jsn=2291

 

I used a catalogue that derives their illustrations and parts direct from MOPAR. It was listed as drain plug in the transfer case section and illustration. I also used 2008 JK as your profile indicates such. That's what was used for my reply.

 

Fman this sucks I cannot get this thing off. But I did notice it was steel so I will weld to it the #10 this week and crack it off that way hopefully. What a PITA.

 

Appreciate it sir. For $6 I'll roll the dice. It's probably the correct part but rock has the wrong picture.

 

Well for anyone dealing with this. Welding the #10 was an easy fix. Came right out.

For my 2008 JKU the transfer case fill and drain bolt are the same and the correct part number for mine was Mopar 68001627-AA

Just order 2 and you can change them out. I would say after 180k or so it's $20 of cheap insurance to make sure you don't have to go through what I did.

https://www.rockauto.com/en/moreinfo...69192&jsn=2794

 

That's certainly one way to skin the cat. I can't recall the last time I had mine out, maybe at 120k with the first clutch and TOB? Maybe it's time to crack them loose and make sure they move.