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Old 06-03-2012, 08:17 AM   #1
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fill plug

Stripped the fill plug on my tcase to crap any idea how to get it out? Thanks

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Old 06-03-2012, 08:32 AM   #2
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sounds like you may have to drill it out..

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Old 06-03-2012, 09:09 AM   #3
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Wouldn't that put shavings in the tcase
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Old 06-03-2012, 09:39 AM   #4
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Quote:
Originally Posted by firedogkp View Post
Wouldn't that put shavings in the tcase
Might be best in that case to remove the back half of the case, if the treads are messed up on the case side you will need to re tap them, or if its bad enough I am thinking new rear cover...

Hoping someone else has a far better idea...
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Old 06-03-2012, 09:44 AM   #5
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Cool
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Old 06-03-2012, 11:06 AM   #6
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Did u strip the threads or the plug
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Old 06-03-2012, 01:25 PM   #7
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The head on the plug
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Old 06-03-2012, 01:44 PM   #8
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There are a few things you can do before you drill it completely out.

Here are things I've done.

Cut off wheel - cut a nice side slot in the head of the bolt, or hammer a slightly smaller socket on and use a manual impact driver and the biggest flat-head bit (or the smaller socket)you can find..
This is BY FAR the most useful tool I have EVERY owned for my jeep. I cannot stress how many times this thing has saved my life. Every bolt I encounter (even the track bar bolts) I've hit 2 or 3 times with this thing and was able to get them off. I encourage everyone to get one of these.
Impact Driver- Craftsman-Tools-Auto & Mechanics Tools-Auto Specialty Tools


Weld a bolt to it - Many times I've welded or had someone weld another bolt to it and now you have another bolt to round off.

Extractor set - more difficult, but I've done it many times. Start by drilling a pilot hole with a small bit in the head of the bolt just a few 16ths deep. Then step it up to a manageable size you thing think the extractor can handle (torque)
12 Piece Screw Extractor Set


I have yet, and will never drill into a Tcase, diff, or engine for sake of a stripped head.
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Old 06-03-2012, 02:11 PM   #9
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There are also twist sockets you can get you hammer them on and turn out the nut or bolt. It's a fluted socket so the harder you turn the more it bites in.
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Old 06-03-2012, 03:40 PM   #10
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I thought about the welding part now with that is there a replacement plug?
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Old 06-03-2012, 04:04 PM   #11
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Quote:
Originally Posted by firedogkp View Post
I thought about the welding part now with that is there a replacement plug?
Autozone, Napa, advanced, any auto store can get one or have one in stock.. nothing really magical about the plug.
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Old 06-03-2012, 04:45 PM   #12
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No just getting it out lol

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