OK, I could use some help on this one in case anyone has come across the same situation, or has some ideas. Trying to do a fluid service on the transfer case as the PO hadn't done it. Here's the rundown at this point:

- 2003 Disco II
- Have not touched the drain plug at all - you always, always start by making sure that the fill bolt comes out first
- Already have the frame cross member off to reach the case and drain plug as the cross member covered access to half of the fill plug and doesn't allow the 1/2" drive to reach it (tons of penetrant used on the cross member bolts over the course of two weeks with daily spraying, and two of them still sheared off - one that I was able to get out with an extractor, the second isn't budging and that will be another battle)
- Fill bolt is frozen in place - I've sprayed it with penetrant for the last seven days and taken daily tries at getting it to move, but no luck
- Have to use a 1/2" drive universal joint to reach the fill bolt on my Disco - there's absolutely no way to reach it directly, with a short extension, or clearance for anything else. Amazes me that LR didn't make it so you could use a short 1/2" drive extension to reach it directly instead of having to employ a universal joint, but like a lot of things on LR's that would make it too easy!
- I've tried using various length breaker bars, hitting a standard sized ratchet with a large rubber mallet, and inserting the universal joint and a short extension and tapping with a hammer (responsibly and without too much force)
- I can't get the fill bolt to move at all

Any ideas? Experience with a similar situation and/or insight would be very appreciated. Thanks.

 

I use a serpentine belt 1/2 bar with a cheater pipe on it. It fits into the tight space perfectly. You might wanna try removing it with the TC warm.

 

It's been quite a while since I did this (8 years, I know, I know), but I recall putting the square drive of my 1/2-inch drive torque wrench directly into the square recess of the plug and it came out without too much trouble. No wobble extension, no nothin'. Best4x4's 1/2" serp belt tool would be even lower profile. Good idea, but I don't own one.

 

That what I use a 1/2 inch serpentine belt tool, works really well.

 

Serpentine belt tool and cheater bar worked like a charm. Thanks for the idea Best4x4! I really appreciate it!

 

I do the same as mln01, 1/2" drive ratchet directly in the plug. I think I had to give the parking brake cable a nudge to create the room to get it in there.

Slow, steadily increasing pressure is a safer approach, than shocking the plug, to get it to break free. Applying some heat to the plug should help, too.

 

No problem! I've also used a 1/2 breaker bar with just a flip/swivel head to remove em, but the 1/2 serpentine belt tool works like a charm as well and it's a breeze to maneuver into place