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transfer case drain stripped help

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Old Mar 1, 2014 | 10:28 AM
  #1  
TOM R's Avatar
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Default transfer case drain stripped help

Well swapped fluids in rears , tc drain was barely snug when removed, went to reinstall and at hand tight it stripped , we cannot get it out, ideas? We tried pull and twist with vise grips no such luck
 
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Old Mar 1, 2014 | 11:04 AM
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that sucks......pull harder while unscrewing..
I have a of lh tap and die set for junk like that. i would put a small bolt in the center to have more twisty pully leverage
 
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Old Mar 1, 2014 | 11:37 AM
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Pull the inspection plate and push at it from the back.
I have the reverse problem in my '96. When my brother still owner it he tightened the drain plug and sheared the head off the bolt. It didn't leak so we left it to fight with it a different day. I'm guessing at some point I'll need to drill it out and replace it.
 
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Old Mar 1, 2014 | 04:34 PM
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Removing cover was a waste of time, there is a giant gear there

Got the copper washer broke off and got under the bolt head wit a panel tool, looks like a screwdriver

Bolt snapped off about 1/4"+ bolt head so we will try to just refill and hope for best for now

Btw the right stuff is a bitch to get off didn't leak though
 
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Old Mar 3, 2014 | 11:32 PM
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Put a threader into the drain plug hole - a tap.
try to get the treads back in good order.
 
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Old Mar 4, 2014 | 06:38 AM
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Just going to leave the sheared off bolt in there?
 
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Old Mar 4, 2014 | 07:14 AM
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TOM R's Avatar
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Yup leaving the sheared bolt for now, plugged the hole with right stuff so far no leaks, 5* this morning and I am still down 1arm so we can only get so much done, spring will be busy I am gonna have to buy a left drill bit to drill this bolt hopping it just comes out

Telling ya never seen a bolt break like this, the end looks machined where is broke
 

Last edited by TOM R; Mar 4, 2014 at 07:46 AM.
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Old Mar 4, 2014 | 11:29 AM
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Finally something I can help you with!! Back it out with a big easy out & tap the threads for a bigger plug (Autozone has one). I did the same thing (was very careful with the fill plug with all of the warnings on here & not so much with the drain plug and I stripped & forced it into submission), but mine leaked. After the repair, there was no drips.
 
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Old Mar 4, 2014 | 11:50 AM
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Good to know, what size drill and tap did you use? Sucks the bolt cannot be accessed from inside the case
 
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