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Old 05-10-2014, 09:06 PM   #1
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transfer case fill plug stripped

Went to change the fluid in the transfer case, found the 10mm hex fill plug was stripped. The hex just spins in the hole.

Tried hammering the hex bit into the hole, still spun.

Any suggestions?

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Old 05-10-2014, 09:21 PM   #2
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Big o easy out, replacement plug.

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Old 05-10-2014, 10:14 PM   #3
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Quote:
Originally Posted by AdamLC View Post
Big o easy out, replacement plug.
Had to do this to 00 a couple of years ago. Only place I could find the replacement plug was from the dealer. It is NOT a pipe thread like the fill plugs in a D44 so you can't get one at the hardware store. Had them order me a couple of spares.
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Old 05-11-2014, 01:28 PM   #4
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When I bought my Jeep the fill plug was also stripped, I ended up welding a 1/2" bolt to the plug and it came out effortlessly. The heat from welding loosened up the plug. New plug form the dealer was only a few bucks.
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Old 05-11-2014, 05:27 PM   #5
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I just welded a nut on the plug. Been using it that way for about 10 years lol.
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98 TJ, stretched, dented and willing.
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Old 05-11-2014, 06:00 PM   #6
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Or once out get plugs from a 1995 or older transfer case same threads but a big 1&3/16 aka30 mm hex head
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Old 05-11-2014, 06:03 PM   #7
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You are correct they are straight threads not a pipe thread taper
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Old 05-11-2014, 06:15 PM   #8
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OD on male threads is just under .860" and threads are either 1.5 mm or 16 tpi, the threaded section so short both gauges match well.

nice thing about hex plugs is they have a sealing washer shaped seal
Under the head

All np231 np241 and np242 I have seen have these same plugs so easy to find at u pull it
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Old 05-11-2014, 07:25 PM   #9
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Time cert will give you same size thread for factory plug. I use it on oil pans , diffs, head bolts. If done correctly works fine.
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Old 05-11-2014, 07:26 PM   #10
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Time cert?
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Old 05-11-2014, 07:51 PM   #11
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It's a steal threaded insert that gives you factory thred.
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Old 05-11-2014, 08:20 PM   #12
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Not sure of manufacture but google it they have kits you drill larger size and install insert for correct thread size. They make many sizes comes with everything you need but the drill. Like I said I use them for all f't up holes spark plugs, head bolts, and anything you have messed up.
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Old 05-12-2014, 11:23 AM   #13
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I think the tc case threads are OK he stripped the internal Allen wrench hex

Drill and easy out should work as long as hole small enough it does not get into the case threads then a new plug

Heat may help as aluminum case should expand more than steel plug making fit looser just not hot enough heat to approach where aluminum softens and begins to melt

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