Transfer Case Fill Plug Problem
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Laughing Gas
Joined: Jul 2012
Posts: 856
Likes: 63
From: Los Angeles/Ventura, CA
Transfer Case Fill Plug Problem
Since my last thread got lost ...
2001 F-350 7.3 4WD. Transfer case made by New Process Gear, model 271L, serial #F8147??95HB, manuf date 10/11/00 3, ratio 27.2
I can get the plug out, but can only get it back in to 60%. Is it OK as is? Is the fluid in the transfer case under high pressure? Any help would be appreciated.
The plug does not appear cross threaded. Nor do the threads on the case appear damaged (though I can't be sure).
I have not tried to torque down on the 10 mm Allen wrench as I thought that might make any problem worse.
I have applied penetrating oil/lubricant to the threads and wiped the back before reinserting the plug. That allowed me to get from 50 - 60%.
It's currently about 90 degrees in Los Angeles where the truck sits.
I've got two new plugs on order.
2001 F-350 7.3 4WD. Transfer case made by New Process Gear, model 271L, serial #F8147??95HB, manuf date 10/11/00 3, ratio 27.2
I can get the plug out, but can only get it back in to 60%. Is it OK as is? Is the fluid in the transfer case under high pressure? Any help would be appreciated.
The plug does not appear cross threaded. Nor do the threads on the case appear damaged (though I can't be sure).
I have not tried to torque down on the 10 mm Allen wrench as I thought that might make any problem worse.
I have applied penetrating oil/lubricant to the threads and wiped the back before reinserting the plug. That allowed me to get from 50 - 60%.
It's currently about 90 degrees in Los Angeles where the truck sits.
I've got two new plugs on order.
Post Fiend
Joined: Nov 2007
Posts: 9,549
Likes: 14
From: Payson, AZ
Just because you can't find your last thread doesn't mean it is lost. It's right HERE. All I had to do was left click on your username and in the drop down left click on Find all posts by djed.
I would take the plug to a good hardware store and try to get a matching thread chasing tap to try and repair the t-Case threads.
Is there a Fastenal store near you?
Edit: I just checked - Fastenal 5917 Olivas Park Drive, Suite D&E ,Ventura, CA 93003
I would take the plug to a good hardware store and try to get a matching thread chasing tap to try and repair the t-Case threads.
Is there a Fastenal store near you?
Edit: I just checked - Fastenal 5917 Olivas Park Drive, Suite D&E ,Ventura, CA 93003
Thread Starter
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Laughing Gas
Joined: Jul 2012
Posts: 856
Likes: 63
From: Los Angeles/Ventura, CA
Thank you for the tap suggestion. I've never done it before but am open to trying it.
The thing is, in another post (https://www.ford-trucks.com/forums/4...sfer-case.html) SpringerPop seemed to suggest these plugs are tapered.
If so, would a tap still be appropriate?
The thing is, in another post (https://www.ford-trucks.com/forums/4...sfer-case.html) SpringerPop seemed to suggest these plugs are tapered.
If so, would a tap still be appropriate?
Lead Driver
Joined: Sep 2005
Posts: 9,399
Likes: 188
From: Norco,CA
It goes back to how far the plug was in before, how easy was it to get out. It should just go back in as before. You don't burn these things in just snug in . If the plug is tapered, that is different then the hole. Take a small brush, just make sure the threads are clean and not crossed.
Post Fiend
Joined: Nov 2007
Posts: 9,549
Likes: 14
From: Payson, AZ
I'm talking about a thread chasing tap that will help clean and hopefully straighten out the threads in the t-case, not cut new threads. If the plug is tapered it is probably an NPT thread and you should be able to find a tap to match. Take the plug to Fastenal.
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Laughing Gas
Joined: Jul 2012
Posts: 856
Likes: 63
From: Los Angeles/Ventura, CA
Went to the Fastenal store this afternoon.
In case anybody needs to know, the plug measured 22mm by 1.5 pitch.
Unfortunately, the price was about $67 plus tax. I'm going to evaluate other purchasing options.
In the meantime, I'm going to give one more pull on the ratchet and watch for leaks.
I would still like to know if the transfer case fluid is under pressure.
Thank you.
David
In case anybody needs to know, the plug measured 22mm by 1.5 pitch.
Unfortunately, the price was about $67 plus tax. I'm going to evaluate other purchasing options.
In the meantime, I'm going to give one more pull on the ratchet and watch for leaks.
I would still like to know if the transfer case fluid is under pressure.
Thank you.
David
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Post Fiend
Joined: Nov 2007
Posts: 9,549
Likes: 14
From: Payson, AZ
The t-case ATF is not under pressure.
Was it 67 bucks for the thread chaser tap or a new plug?
Was it 67 bucks for the thread chaser tap or a new plug?
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Laughing Gas
Joined: Jul 2012
Posts: 856
Likes: 63
From: Los Angeles/Ventura, CA
The plug was $3 and can be found at QU10939 New Process, New Venture Transfer Case Drain or Fill Plug . Shipping added about $9 to the total price. Two Ford dealerships in my area (Galpin and Sunrise) couldn't locate what I thought was the correct part and insisted the plug was a square drive with a lip???
The tap was $67 + tax. Sorry for the confusion.
The tap was $67 + tax. Sorry for the confusion.
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