Broken transfer case drain plug - Defender Source
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  #1  
Old August 5th, 2012, 10:00 PM
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Jeff Huff
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Broken transfer case drain plug

Doing some work on the truck and decided I would swap the fluid in the t-case...put a wrench on the drain plug, turned and it was really easy but didn't really come out at all. I don't remember overtightening on the last install but the plug was definitely broken. I got a small flat blade screwdriver behind the head and kept working it until I got what appears to be around 1/2 of the plug out. I then grabbed the extractor kit and after having two different drill bits render themselves useless I am frustrated and somewhat stumped. I plan to hit the store for some "nicer" drill bits tomorrow but anyone have any ideas? Maybe try heating before drilling?
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  #2  
Old August 6th, 2012, 05:49 AM
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Jeff-
Had the same thing happen to me. To get mine out I had to drill a very tiny pilot hole and enlarge that enough to get the extractor to work-in doing so it also popped the magnet off the end of the bolt so it was loose in the TC. Just make sure you get that out; which will probably mean planning on pulling the inspection plate off.
r-
Ray
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  #3  
Old August 6th, 2012, 07:37 AM
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Quote:
Originally Posted by JSBriggs View Post
This one? http://www.defendersource.com/forum/...3&d=1343707481

Is whats left of the drain plug solid or hollow? I as i recall its hollow, if so snap ring pliers would work, if not, drill and easy out. Should be easy going as its brass.

-Jeff
What's left is solid and very hard, definitely not brass. I had some relatively sharp bits in my ez out kit that are now really dull!

------ Follow up post added August 6th, 2012 07:38 AM ------

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Originally Posted by Ray_G View Post
Jeff-
Had the same thing happen to me. To get mine out I had to drill a very tiny pilot hole and enlarge that enough to get the extractor to work-in doing so it also popped the magnet off the end of the bolt so it was loose in the TC. Just make sure you get that out; which will probably mean planning on pulling the inspection plate off.
r-
Ray
Thanks Ray. I plan to swing by and grab some drill bits this afternoon but will make sure I get some smaller bits too.
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  #4  
Old August 6th, 2012, 07:46 AM
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My experience was the same; I got on it with what I considered a small and sharp bit; and got nowhere b/c of the harnness of the plug. When I came back with one of the smallest in my selection it finally got a good hole started and that let me widen it slightly before going to the extraction bit.

All of which contributed to the magnet getting popped off though!
r-
Ray
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  #5  
Old August 6th, 2012, 12:41 PM
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I think the last time I encountered this I punched the old plug into the t-case and removed the broken pieces with the bottom plate off. I just went to NAPA and got a bigger drain plug, and drilled and tapped the T-case to accept the bigger plug.
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Old August 6th, 2012, 02:10 PM
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Originally Posted by Jymmiejamz View Post
I think the last time I encountered this I punched the old plug into the t-case and removed the broken pieces with the bottom plate off. I just went to NAPA and got a bigger drain plug, and drilled and tapped the T-case to accept the bigger plug.
How much of the plug did you have left in the t-case? I would consider this a last resort but after messing with this for a while I did consider it!
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Old August 8th, 2012, 09:34 AM
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After dulling/breaking a few more drill bits I decided to take out some aggression...took a punch and 5lb hammer, gave it a whack and voila, no more plug in the hole! The outer threads were still ok but the 12mm plug wasn't holding as well as I would hope so I tapped for 1/2" plug and seems to be all better now. I guess only time will tell!
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  #8  
Old August 8th, 2012, 11:11 AM
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Jeff, we fixed a transfer case that suffered a similar fate by fitting a Time Sert threaded insert. Like a Helicoil, but better. I could send you the whole kit- drill bit, taps, counterbore, insert, and installation tool if you're interested in keeping an original drain plug set-up.
Just email the address and I'll send it out today.
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Old August 8th, 2012, 01:37 PM
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Awesome, thanks Trevor! email sent
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  #10  
Old August 8th, 2012, 06:41 PM
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Are you sure you got all the bits out? Consider giving it a flush before putting too many miles on it (like say a trip to Rausch)
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Old August 8th, 2012, 08:52 PM
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Originally Posted by cgalpin View Post
Are you sure you got all the bits out? Consider giving it a flush before putting too many miles on it (like say a trip to Rausch)
I filled the bottom of the case (with the inspection cover off) and let it all drain out then reinstalled the inspection cover. I plan to fill the case with cheap oil, drive a cautious few miles and then drain and re-fill. if there are any particles in the drained oil I will probably consider pulling the inspection cover again
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Old August 8th, 2012, 09:05 PM
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If it is just aluminum particles I would not stress too much about it. Unless they are super huge. You did pull the bottom cover off, right?

Quote:
Originally Posted by jefhuf View Post
I filled the bottom of the case (with the inspection cover off) and let it all drain out then reinstalled the inspection cover. I plan to fill the case with cheap oil, drive a cautious few miles and then drain and re-fill. if there are any particles in the drained oil I will probably consider pulling the inspection cover again
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  #13  
Old August 8th, 2012, 09:16 PM
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Quote:
Originally Posted by Ren Ching View Post
If it is just aluminum particles I would not stress too much about it. Unless they are super huge. You did pull the bottom cover off, right?
Yes, pulled the cover and removed the magnet along with several small pieces from the areas where I could get my fat fingers!
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