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Transfer Box Fill Plug

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Old Nov 2, 2015 | 10:36 AM
  #1  
DiscoCam's Avatar
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From: SF Bay, California
Default Transfer Box Fill Plug

I always had a shop change my transfer box fluid and it needs to be changed again. I've decided to do it myself now. How do I get to the fill plug? My rachet doesn't clear the brake drum. Does the plug require a lot of force to open?
Thanks in advance.
 
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Old Nov 2, 2015 | 10:41 AM
  #2  
ZGPhoto's Avatar
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Wobble socket IIRC, 1/2" drive I believe. It's been several months since I've looked last
 
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Old Nov 2, 2015 | 10:49 AM
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From: Boston Strong
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use a 1/2 x 12 inch long ext. and come from the back up and over the cross-member, i believe if you put a 1/2 universal on the end of the ext. it makes it even easier to line up
 
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Old Nov 2, 2015 | 10:58 AM
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Just tried the 12 inch extension with a U joint and I was able to reach the plug. However, it's stuck on there pretty good. Is that normal?
 
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Old Nov 2, 2015 | 11:04 AM
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From: Boston Strong
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yup, more leverage, longer ratchet
 
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Old Nov 2, 2015 | 11:23 AM
  #6  
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I used a tailpipe on the end of my ratchet and it worked.
Thank you everybody.
 
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Old Nov 2, 2015 | 07:23 PM
  #7  
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Looks like I spoke too soon.
I thought I broke it loose but it looks like I only broke the U joint. I tried using WD-40 on the plug, didn't help either.
Any ideas?
 
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Old Nov 2, 2015 | 07:56 PM
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PB Blaster. I saw someone on here mention something stronger than PB recently, but I can't remember the name. Anywho, try some PB with that longer breaker bar and no U-joint.
 
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Old Nov 2, 2015 | 09:22 PM
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I used a serpentine belt tensioner tool and it worked great. It is flat and skinny to fit between the transfer case and the brake line and it was like 20 inches long + a 10 inch extension or so...and with all that leverage I just barely broke it loose. Here's the link to the one I bought. The extension is a 1/2" drive. So you mount that onto the long 3/8" drive to get some awesome leverage. It truly is a great tool to have for this:

http://www.amazon.com/OEMTools-27115-Serpentine-Belt-Tool/dp/B0014WDKQ4

Originally Posted by DiscoCam
Looks like I spoke too soon.
I thought I broke it loose but it looks like I only broke the U joint. I tried using WD-40 on the plug, didn't help either.
Any ideas?
 
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Old Nov 2, 2015 | 10:03 PM
  #10  
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From: St Louis MO
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Originally Posted by Andrew0
I used a serpentine belt tensioner tool and it worked great. It is flat and skinny to fit between the transfer case and the brake line and it was like 20 inches long + a 10 inch extension or so...and with all that leverage I just barely broke it loose. Here's the link to the one I bought. The extension is a 1/2" drive. So you mount that onto the long 3/8" drive to get some awesome leverage. It truly is a great tool to have for this:

Amazon.com: OEMTools 27115 Serpentine Belt Tool: Home Improvement

X2 on this. I fought with my fill plug the first time I did the service. I got to thinking, "Is there anything else I can use that has a 1/2" square drive?" After a few beers, I remembered the serpentine belt tensioner tool. I rented one from where I work (O'Reillys) and had the plug out within minutes.

Forget WD-40. I've mentioned it before on this board about my new go-to penetrant in a can. https://seafoamsales.com/deep-creep/ I used to use PB Blaster, but this stuff makes the PB look like water.
 

Last edited by lordmorpheus; Nov 2, 2015 at 10:07 PM.
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