I am unsure who it was that originally mentioned it, but the ONLY way to remove the filler plug on the transfer case is to use a serpentine belt tool!! It is fantastic, you just slip the 1/2" drive attachment into the filler plug, then slide the thin 18" long handle up there over it, pull to loosen, repeat as necessary and real quick you have it out. No problems with limited room and the long handle works great like a breaker bar... and, as a bonus, if you have a 16mm combination wrench with the ratcheting box end, you can get it loose or tight even faster.


Thank you for the great suggestion!!!


Now, getting the gear lube in the case was another story.... but finally got that going fine also... my pump I used for the tranny fluid just would not pump the 75w140 lube...

 

My hand pump works well for the 85w-140 it is just hard to pump and takes like forever.

 

That was the problem with the pump for my drill... it took almost an hour and a half to do the front differential... therear I could get to with the bottles and took like 4 minutes... the transfer case I tried all kinds of things and mostly ended up with royal purple oil all over my drive (thats expensive). Finally remembered that I had an electric pump from when we had a waterbed, the hose fitting on the outflow fit into the transfer case (too big for the transmission) it does like 3 gallons per minute of water, did the 5 pints of lube in about 2 minutes..... now I will see what the lube does to the impeller.

 

My pump is a hand pump, like a bike pump, took like 10 min per diff and about 10 for the t-case.

 

My hand pump looks like the pump on a bottle of hand soap and took a while to fill the t-case but it worked. The pump screws right on to the bottle so I didn't have to worry about spilling the gear lube.

 

I remove my filler plug with a 1/2" drive ratchet every time. Never any problems.
As for a gear oil pump, this works great, fits right on a 5 gal pail of gear oil.

 

I like that one also

 

so the transfer case also uses gear oil like the ones for the front and rear differential? Just want to be clear before i change mine..

 

Spike,
this is what you need:

http://www.oem-tools.com/product_inf...oducts_id=1610

it's about $8.00 at Autozone. You can pop the back off and pour the fluid right into it OR use it in siphon fashion. It's very well made for the money and you can squirt out 16 OZ of fluid in about 3 seconds! (although it does depend on the weight of the fluid).

HTH.

Highly recommended.

As for removing the x-case plug, I have had no problems using 1/2" universal. I just added fluid last night and it was in and out pretty quickly...now trying to do it when you don't have light is kind of a task because of that stupid brake drum being in the way.

 

I believe it was I who suggested the serp. belt tool, thats how i eventually got my plug out, cuz it seems that whatever combination of universals and extensions and wratchets
didnt work so i asked the neighborhood oil changin' guy what he could do and he came up with the idear, worked great