np-242 transfer case fill plug.

[skinner]

OK got this morning to do a oil change and t-case fluid change. went to open the fill plug on the t-case and it is frozen solid. soaked it in pb blaster and tapped on it with a hammer and it will not break loose. Its a 3/8 allen plug that is pretty chewed up so I don't want to make it worse.

here is a pic

after further trying it is now rounded out all together. I have already ordered a new plug but what will be the safest way to remove that damn thing. I may try a extractor first and if that fails drill it out and big as I can tap it and thread another bolt in. unless anyone else has a better idea.

 

[kastein]

Try cutting notches into it on opposing sides of the hole and then using something as a large screwdriver. Doubtful it'll work...

You could also weld a piece of aluminum stock to the thing and try turning that but that might damage the rest of the case. Luckily it's about a hundred bucks for a whole 242 at the junkyard if you can find one, and a 231 drops in pretty easily if you can't.

 

[ehall]

heat that sucker up, drive a torx bit into it, and crank it out

 

[Flyfisher]

If you find yourself in a real bind...I have an NP242 spare...would sell reasonable....plus shipping, of course. HaHa

 

[austinaubinoe]

when's the last time you changed the ATF? When you do get it open, spread on the anti seize!

 

[RCP Phx]

When you do get it open, spread on the anti seize!

Anti-seize would be a bad idea,but Teflon tape would go a long ways!

 

[austinaubinoe]

sorry for the bad tip... hate to ask whats wrong with anti seize on the t case........

 

[soopergoober]

You could also try jb welding the allen key in there, let it set, then give it hell? Just don't get any jb weld near the threads.

 

[skinner]

I got the F'er off took a propane torch and #5 screw extractor to do it but by god its out. LOL.

RCP Phx why is anti-seize a bad idea?

 

[kastein]

I'm thinking that it's not so good for the transfer case internals once it gets into the fluid, since it contains microscopic metal or graphite particles.

 

[RCP Phx]

I'm thinking that it's not so good for the transfer case internals once it gets into the fluid, since it contains microscopic metal or graphite particles.

We have a winner!