Engine/Transmission (1998.5 - 2002) Transfer Case Fluid Level

[Seafood10]

I had some trans. upgrades performed and afterwards the TC seal did leak a little and I topped off the level. Well I am heading down to Mexico over the holidays and went tocheck the level yesterday and I screwed up, I was rushing and used a 3/8 allen bit rather than the required 11mm and sort of rounded out the plug.

So I have a couple of questions, should I be over concerned about the level in there and if so, what would be the best way to remove the plug? I tried to bang in the 11mm bit but it just wouldn't get enough bite to unscrew the plug.

I have a little tig welder and was thinknig about welding the bit to the plug but am not too experienced with weldingPlease help.

thanks

Sean

 

[RRees]

1. Get some JB Weld

2. Use the same 3/8 allen bit.

3. Let the JB Weld set up.

4. Replace old plug with new one.



Put the JB Weld in the plug, then tap the 3/8 allen bit into the plug with the JB Weld. Let it cure/set up. Then remove plug and replace with new plug.



Hope that works.

 

[Seafood10]

Hey Thanks, will try.

 

[RRees]

It's a long shot. I hope it works for you.



I'm trying to visualize if an easy-out might work in your case. Get one that barely fits and as you thread it in, it might "bite" enough to grab and allow enough pressure to be applied to remove the suspect "plug".



Good luck.

 

[DIESELWRKS]

I tried a couple of ways but the easiest was I welded a nut on it and took it off. it took me 2 weeks to get a plug from the dealership so at least I was able to take the plug off and check the level and put it back on untill the new plug arrived. .