Engine/Transmission (1994 - 1998) Removing a stuck filler plug from transfer box

[Crowhurst]

A few months ago I checked the level of the transfer box ATF, and replaced the filler plug, using a hex socket in a torque wrench to the FSM specified torque. Now I can't remove the plug to check the level. When I tightened the plug the temperature was perhaps 30 degrees colder than now, but I have no clue as to whether that is relevant. I'm using the hex socket with a cheater bar, with no success. The hex hole in the plug is threatening to round out, so I've ordered a new plug to collect tomorrow.

I'd be grateful for any advice on removal. I'm in the middle of a field with my travel trailer, so I don't have any fancy equipment. I could use some PB Blaster, and I've a small high pressure propane flame for lighting the gas hob.

Back home in the UK I have an impact driver that one hits with a hammer, and also some "screwgrabber" which is a granular paste to use with worn fasteners. Advice, please, before I get ugly with it.

Thanks, Nick.

 

[Bob4x4]

Be carefull,that is a straight thread in the case and a pipe thread on the plug
A high quality hex bit(10mm) that fits very smug will get it out if it still fits tight

 

[BDaugherty]

an impact wrench will work wonders. also use a standard socket to get a half size bigger so it will be tighter. for example if the plug is 10mm, try a 7/16". also, hitting plugs flat with a hammer will loosen them up, but be careful with the aluminum. heat may help. the plugs are pipe thread right? or do they have a shoulder?

 

[seafish]

Nothing wrong with spraying a little Kroil penetrating oil on it first first. Or you can use some freshly shaken 50/50 acetone/atf mix on it.

 

[GAmes]

Unless there is evidence of a leak I would leave it and wait until I got back home.

 

[Crowhurst]

Good ideas, thank you all. I'll try some of them tomorrow. The plug doesn't have a shoulder. Unfortunately I can't leave it until I get home. I'm snowbirding in FLA, and home is across the Atlantic in England! I keep my truck in the USA for use in the winter.
Thanks again.
Nick.

 

[GAmes]

In that case it might be time to invest in a second impact tool. Some auto parts stores have loner tools also, maybe check them out.

 

[mfurrh55]

Why are you checking it again?, is it leaking?, if not leave it alone, Monte

 

[Crowhurst]

Why are you checking it again?, is it leaking?, if not leave it alone, Monte

I have some leaking ATF by the gasket below the drain plug. The surrounding nuts and bolts are all tight, so I need to establish if the leak has lowered the level in any serious way.
By "impact hammer", is that as I understand it in England, that is one where you hit the end with a hammer, or are we talking about an air tool? I don't want to risk cracking the case by using a wrong method. Today the dealer discovers that the new plug is on back order, so I'm waiting until next week.
Nick

 

[Crowhurst]

I got the plug out this morning. I used an artist's very small brush to put PB Blaster round the thread, but avoiding the hex socket hole. I have previously used a 3/8" hex drive to insert and remove the filler and drain plugs. This equates to 9. 5 mm. Taking the advice above, yesterday I bought a 10mm hex drive. It had to be hammered into the hex hole, but the plug then came out with with a ratchet and a cheater bar. When I get the new plug I'll see if the 10mm will fit. Many thanks for all the advice.
Nick.