stuck t case filler plug
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stuck t case filler plug
we have the n208 tcase on 84 f250. filler plug is seized in, slightly rounded. the 30mm shallow socket doesn't have snug fit..there's play in it. not wanting to worsen this situation by ham handed ignorance, we're asking for any helpful suggestions. 
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From: Virginia
It's probably a female square. I would go to a metal shop or somewhere and get a assortment of keystock or some square metal cut in short pieces. Make sure it's nice and square with sharp corners, and take a hammer and drive it in place. Then get a large crescent wrench and try to bust it loose. A metric 13mm key might be large enough to drive in.
We all need to be careful also tightening these plugs up. I worked on a transfer case that had a persistent leak around the drain plug, and someone had over-tightened the plug and cracked the case. I ended up filing the crack out, putting some jb weld in the crack, and then installed a hex bushing while the jb weld was still runny. Then put a smaller pipe plug in the bushing.
We all need to be careful also tightening these plugs up. I worked on a transfer case that had a persistent leak around the drain plug, and someone had over-tightened the plug and cracked the case. I ended up filing the crack out, putting some jb weld in the crack, and then installed a hex bushing while the jb weld was still runny. Then put a smaller pipe plug in the bushing.
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stuck t case fill plug
it's the 30mm hex head. supposed to use the 30mm 6 side shallow socket. right. that fits beautifully on the undamaged drain plug. the p.o. over torqued the fill plug, so it is too tight to move without damaging it. pipe wrench...not. just slipped off and chingered head a little. as I said, I am leery of the slop in the fit of 30mm on this damaged head.
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From: Virginia
30 mm is about 1 3/16 inches. Sometimes I drive a american socket that is a little smaller onto a worn fastener or the other way around. Sometimes you can take a file and clean the nut up, and by the time you do that a one size smaller socket will fit.
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I've always used a 1 3/16" socket on those. Its so close to 30mm though they are virtually the same. I'd try that first, otherwise as already suggested try hammering a slightly smaller socket onto it. If all else fails you could weld a nut to the back of the plug. You have plenty of surface area so I'd use a 1/2" nut which would allow enough room to fill the center of the nut in without burning the edges of it off. Then you could put a 3/4" socket over the nut to break it loose. Or, weld a short bolt to it. That would stick out more but you wouldn't have to worry about damaging the corners from welding it.
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stuck t case fill plug
OK, looks like going to a slightly smaller socket, after doing some filing on the head. 6 side socket and hope it works. btw...have used a whole lot of blaster on the thing. thinking of the atf/ acetone combo.
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I have been trying the atf/acetone mixture and it actually does work well. What I can't stand is the stink. If I could find a oil that doesn't stink as bad as tranny fluid, it would help.
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I can't wait to try it, soon as the weather is better. it couldn't stink as bad as gear oil and lube grease. not a real emergency at this point since the p.o. had fairly recently swapped out t cases before we bought truck. just feels good to have all new fluids where they belong.
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