So I'm just about done with my 60k service, saving the easiest for last, replacing the transfer case fluid. Unfortunately I failed to check both the 10m drain and fill plugs before dropping the fluid. Obviously, I dropped the fluid only to discover the fill plug head is stripped. How do I get the 10m allen head plug out? I'm about to go down and spray it with WD40 and let it sit with the hope it will loosen up enough that I can get it to turn with what's left of the head but if I were a betting man I would bet that isn't going to work. Any suggestions on how to extract the plug will be appreciated. Thanks!

 

thats a bitch in the past i have used an over sized torx bit and tap it in snug with great success that being an improper use of tools go to sears and look at some of the nice extractors they have available . soak it real good with wd40 overnight though .i have also used a small chisel before and tap it at an angle to loosen plugs . it can get nasty gettingthem out . last resort is a drill bit coated with lube grease to drill thru the plug the grease will hold metal particles and keep them out of the case then u can use an extractor that goes in the hole you made . a left hand bit if large enough would possibly work too

 

And really worse comes to worse, go to an exhaust shop or a buddies with a welder. Cut down an allen bit, hammer it in like mentioned, and weld the bit into it. Of course, after its out of the t-case. And maybe source a new plug somehow in the next couple years!

 

hey sa29560

if you were going to weld a stud in there do you have to disconnect the battery or anything like that?

sorry to hear about the stripped allen screw. was it already stripped or was it galled? amazing what a nickels worth of anti seize or even pipe dope can do. good luck. i have used a dremmel to make notches across then used a piece of 1/8 steel strip as a screw driver and pliers for leverage.

 

It was already tore-up. Dealer must have done it when they did my 30k service. The real problem is I have no way to get the ATF+4 into the now-empty transfer case. Dumb question, but can I drive the Jeep with the T-case empty?

 

noooooooooo dont drive it ! power is transferes thru it even in 2 wd , that would not be good

 

Best options have already been given....the order to try would be....1>tap in a bigger bit....2>chisel at an angle....3>weld in a bit.

DON'T DRIVE IT EMPTY......unless you've got tons of pocket change around to buy a new t-case.

 

You could use a hack saw blade to cut a slot in it like a scew and ise an impact driver to get it out.

 

Or an angle grinder. But be careful.

 

What you should try to do is find an easy-out that will fit. Could be a long shot finding one that big, but worth a try.