Does anyone know the exact type size (Allen type) you need to open up the filler and drain plug on the transfer case? I have a 3/8 but it is slightly small and getting ready to strip the plug. Just wondering what size you guys might be using so I'm not running around crazy trying to find the right size.

 

if i remember correctly- i thought it was a 10mm

 

Well, I go and buy the 10mm get home it fits in perfect. Righty tighty, lefty losey. The dern filler plug thing completely stripped. It's a perfect circle now. It felt like the metal is very soft almost like aluminum. What gives? The first time I go to check the fluid in it it strips out. Or is it the torque them down so darn tight coming off the line??? I'm just Now how will I be able to get this thing off, and can you buy replacements anywhere? Any good info will be much appreciated.

 

Maybe you can hammer an 11mm in there and work it out? I don't know if you can get an ease out in it without drilling a hole which would be bad cause shavings would go down in there. Probably have to buy another plug from the dealer I doubt you could find a metric one like that at tractor supply or some such place.

 

I think I'd try a spiral flute type bolt extractor first...

 

like jeff said- try an extractor first. if that doesn't work-find a friend that welds- have him tack weld a bolt on the plug-then use the appropriate size socket to get it off. new filler plug will need to be purchased from the dealer. carpenterje- you are correct-the factory tends to over tighten these plugs,etc, plus with the combination of the soft metal used to make these plugs-one must be careful and pay close attention when taking them off!

 

Thanks guys

 

I was able to use a punch that I ground off center to drive it out. Kinda like how you tighten the old chevy dually rear bearing retaining nuts. If you try this be careful.

 

Thanks for the warning. When it comes time for my change I'll lay some penetrating oil on it and get the case warm.

 

If I recall it is a 1/2" NPT plug. You can drive a 7/8" six point socket on it and get it out that way.....If there is plug sticking out that is. It worked on the old DROF once.

Glad you tried the fill plug first. Many times it is best to lightly tap these plugs first to let them know you want them to come out.