Fill plug in 1356 transfer case is stripped

[fatherdoug]

I checked all the fluid levels today in my '89 F-250. But I can't get the fill plug out of the B/W 1356 transfer case. Somebody(not me) used something other than a 3/8 ratchet extension to try to get the fill plug out, so the hole in the fill plug is now completely rounded out on the inside of the plug. I tried a pair of vise grips, but the aluminum plug is just too soft. I am wondering if the threads on the plug were galled, and the plug would just not come out.

I don't have any issues with the transfer case, but I don't like not knowing what the level is in the transfer case.

I got a couple of easy outs to try with the drill bits, which I will try tomorrow if it stops raining.

Anybody have any ideas or experience?

 

[Skandocious]

I was gonna say something like easy outs might be your best bet That sucks buddy, let us know how it goes.

 

[fatherdoug]

Thanks, Chris.

 

[smokey]

I have bumped a few out with a air chisel. I used the pointed bit and bumped it loose.

 

[fatherdoug]

Thanks, but I don't have an air compressor, yet....... I did think about wedging a chisel into the hole and trying to turn the chisel.

 

[nobodyspecial]

If not an air chisel, a regular old hammer and chisel has worked for many different things like that on our farm. dont wedge the chisel in there.

I don't know how to describe this, but just hammer on the outside in a counter clockwise manner to get it to turn out.

 

[fatherdoug]

Update - The easy out worked, for once in my life. The old aluminum plug came right out. I was worried that the threads might also be stripped, as bad as the plug looked, but no, it came right out. AND the transfer case was full of fluid. It cost me $25 for the drill bit and the easy out, and $1 for the plug!

Another question. The only plug I could find to install in the hole was a mild iron plug. Long term, it is probably not good to leave a mild iron plug in an aluminum transfer case. Anybody have thoughts on this?

Thanks everybody for the help and suggestions.

 

[nobodyspecial]

good to hear! nice when things work out like that.

 

[Skandocious]

Yeah if you can find an aluminum plug to replace it, I'd recommend it. Those two metals will expand and contract at different rates which may lead to problems down the road.

 

[TexasRho83]

find an old case somewhere and snag the plug lol

 

[fatherdoug]

My neighbor has one.........? Thanks Guys.

 

[nobodyspecial]

Awesome, thats the kind of problem solving I like to see.