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transfer case fill plug stripped

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Old 10-15-2016, 09:18 AM
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transfer case fill plug stripped

I have a 98 f150 manual transfer case with a stripped fill plug and with winter just around the corner here in Michigan I want this truck to be ready for a that white stuff.so my question is how can I get the plug out
 
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Old 10-15-2016, 07:44 PM
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I assume you mean the HEAD is stripped so you can not grab it. Normal procedure is to use vice grips if the head is exposed and rounded. If this is countersunk and a hex drive (etc), you can drill a 3/8 hole thru the plug and pound and extractor into it and screw it out, or you can get someone to weld a bolt to the plug, then grab the bolt head and screw it out.
 
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Old 10-17-2016, 04:40 AM
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Originally Posted by steve(ill)
I assume you mean the HEAD is stripped so you can not grab it. Normal procedure is to use vice grips if the head is exposed and rounded. If this is countersunk and a hex drive (etc), you can drill a 3/8 hole thru the plug and pound and extractor into it and screw it out, or you can get someone to weld a bolt to the plug, then grab the bolt head and screw it out.
Do NOT attempt to use a screw/bolt extractor. If the bolt/plug stripped out, the extractor will snap off FAR sooner than it would turn a stuck plug. I learned that the hard way on my RX7, when am old M6 bolt broke off in the strut tower. No fluids to mess with and it was very accessible, but it took 2 hours with a drill and dremel to get all the way through the bolt and extractor sufficiently for a M5 bolt to slip through.

If I had to do that on a fluid plug, I'd rather smack myself in the nuts with a claw hammer.

If it's an exposed hex head that rounded off, grab your dremel and grind a couple flats on it for a wrench to fit. Hit the threads with PB Blaster for days in advance and it just might work.
 
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Old 10-17-2016, 06:48 PM
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Originally Posted by Travis S

If it's an exposed hex head that rounded off, grab your dremel and grind a couple flats on it for a wrench to fit. Hit the threads with PB Blaster for days in advance and it just might work.
that's a good idea

you can also use a chisel and hammer on the outer edge, trick is to find a chissel that's about half dull, otherwise to sharp and it'll just take chunks out of the plug.

prolly ought to get a new plug before hand, just in case
 
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Old 10-26-2016, 01:53 PM
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If it's a Allen head plug, find a bolt that fits in it, then weld it to the plug. Then turn it out.
 
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