More T-case fill plug woes

[azcummins]

Finally got around to trying to get my T-case fill plug out, (Dodge almost stripped it out last time I had it in for the faulty T-case output shaft seal replacement).



What I did was JB Weld a 10mm allen wrench in there and let it sit for 24hrs. Then cranked the 10mm allen with a 10 mm open end and the allen backed itself out! All the J-B weld just flaked off!



So now i'm thinking that I should get a new plug and use an EZ out to pull the old plug. Looking at the drain plug which easily backs out, the fill plug is easily in another 1. 5 turns.



So should I EZ out it or take it back to Dodge and ask for a T-case fluid change and let them screw with it?



Note... it has been about 3 months since the service when they screwed up the fill so I figured they wouldn't take responsibility for it.



What should I do?

 

[Rob Thomas]

Didn't we already have this conversation?



https://www.turbodieselregister.com/forums/showthread.php?threadid=41280&highlight=tcase+fill+plug

 

[LSMITH]

I would not use an EZ-out, it will expand the plug making it tighter as you put the torque to it. If you do not have access to air tools to use an impact to get it out I would take a pin punch and hammer into the bottom of the plug. Give it a couple good solid pops, and then try to take it out. Hammering it you are pushing the plug into the threads a tiny bit, and taking some of the engagement out of the threads. That should loosen it up a hair, letting you get it out.





I would go fight with the dealer if it were me, if they broke it I would try to make them fix it.

 

[azcummins]

Yeah we've talked about this before but now I finally got around to trying it and I had no luck so I was looking for other ideas.



I have an impact wrench but I'm afraid to crank on it b/c it is an aluminium housing. I think I'm going to go to the dealer and see what I can get done.

 

[BK]

how rounded out is the "square" drive whole in the plug?





If you can work with it, get a dremel and some of their end metal cutting bits, re-square it and get a set of these...



http://www.thetoolwarehouse.net/shop/SK-19798.html



these are SAE,,, dont know if they come in metric, havent seen them if they do. but if you can get them in metric, you'll have some more inbetween sizes.

 

[azcummins]

Here is the final update guys:



Decided I couldn't be without the truck for the time it would take the stealer to do something about it so I went after it myself.



I tried impacting it out but that just rounded out the plug so then I went for the EZ out and it didn't work. So I drained my fluid, changed the output shaft seal which was bad and then pulled the PTO cover and lifted the truck way to the left. I refilled the T-case with 3. 5 Quarts of ATF and then it flowed out.



I know I'm a . 5 Qt. low so I'm going to put in a fill plug in my PTO cover and fill it from there.



All in all it was a pain, but I learned a lot.



Thanks for all your help.

 

[Rob Thomas]

az,



Yer just not gonna' try the hammer chizel trick, are ya? It works, trust me.



Later, Rob

 

[azcummins]

Rob-



Your Chisel idea sound good. Is it kinda like hitting a jar on the edge of the kitchen counter to loosen it up? We pulled HARD on the plug with the EZ and it wouldn't budge. I'll see if my roommates have a chisel so I can go back to hammering away with a BFH!!!

 

[Rob Thomas]

Yea, it's real simple, ya just hold the chisel on an angle in the corner (or in you case in the divet ) of the square hole, and wackit with the BFH. Remember: lefty loosey, righty tighty.





Good Luck, Rob