Engine/Transmission (1998.5 - 2002) Stripped T-case fill plug

[JFinke]

A pickup I'm working in has a stripped fill plug. How would you remove it? I figure I'll try welding a 10MM allen socket in the hole and give that a try. Hate to take the welder to a snap-on, but the customer will be paying. I thought about welding a nut to the outside of it, but there isn't much room to weld with a decent sized nut. Jake

 

[Supermod56]

I would heat up the case with a torch and try some type of easy out, Snap-On has some short-style easy outs that you pound in with a hammer. Pound it in, and as you heat the case, try to unscrew it, the aluminum should expand fairly quick to get the plug out. Or the turn it with a chisel method if that's all you got.



Tom

 

[jrobinson2]

Use a large nut and weld the inside to the plug.



Jared

 

[JFinke]

I've got the set of snap-on short pound in E/Z outs, but they need more depth than the plug has to engage(I tried them first and just made the hole a little bigger, and the next size needed to be drilled out to go in). I normally would just weld a nut, but I didn't want to make that much heat on the plug, to weld the inside of a 1/2" nut, as it was going into aluminum. I welded the allen wrench into the plug and it came right out. Jake

 

[justinp20012500]

A pickup I'm working in has a stripped fill plug. How would you remove it? I figure I'll try welding a 10MM allen socket in the hole and give that a try. Hate to take the welder to a snap-on, but the customer will be paying. I thought about welding a nut to the outside of it, but there isn't much room to weld with a decent sized nut. Jake

Do you have access to a welder?? Maybe a friend has a small 110v that will work?



Can you take a short 3/8" extension and weld it on the plug? That would make it easy for future services.





Justin