Heelllpppp

[Gadzooks]

The transfer case fill plug (24mm) on my 91 toyota pick up is stripped. Can't get that sucker loose with a 6 sided socket or an open end wrench. I've gone to two tranny shops and neither were any help. I'll be driving from Ottawa to Toronto this Friday night, anyone know of any places open that would be able to get in there, or of a shop open on Saterday in the GTA familiar with this sort of thing??

Gonna need some tcase gear oil soon!!!! :yike

[whateverworks]

Try a flat punch and a hammer if ya can access it ok. Use the punch on the outside diameter of the plug and break it free with a few good clean shots.
Kelly

[Gadzooks]

Try a flat punch and a hammer if ya can access it ok. Use the punch on the outside diameter of the plug and break it free with a few good clean shots.
Kelly


Just to clarify, you saying hit it as if to spin it open?

[whateverworks]

I stripped out the fill plug on the front diff of my 'Kick and this is how i got it out without drilling a hole and using an easy out.
If ya get it on the outter most edge of the plug and angle the punch in the right way it will shock it out. You may have to chase it out with the hammer and the punch once it comes loose depending on the amount of corrosion happened between the steel plug and the aluminum case... Or if your angle of attack gets changed you might have to put a secong knotch in the plug with the punch n hammer.
Kelly

[mudbug]

Can you weld a nut to the plug? Whenever a nut bolt or screw gives me trouble I just weld a nut to it and out she comes ;)

[Gadzooks]

Thanks Kelly, punched er out. I was hesitant at first, but a little effort and I managed to knock it loose.
Awesome.


I stripped out the fill plug on the front diff of my 'Kick and this is how i got it out without drilling a hole and using an easy out.
If ya get it on the outter most edge of the plug and angle the punch in the right way it will shock it out. You may have to chase it out with the hammer and the punch once it comes loose depending on the amount of corrosion happened between the steel plug and the aluminum case... Or if your angle of attack gets changed you might have to put a secong knotch in the plug with the punch n hammer.
Kelly

[whateverworks]

Glad I could help :)
Kelly

[mars_man]

If they haven't been out in a while, it's not a bad idea to heat them up with the torch before even attempting to remove...

[Canadian_zuk]

If they haven't been out in a while, it's not a bad idea to heat them up with the torch before even attempting to remove...


Probably someone like me owned it. . :) I've only used the factory fill plug once or twice. That was long before I found the easy way to replace tranny and t-case juice. I now just pull the shifter and dump the correct amount of fluid down the hole from inside the cab, no lying on my back, no drips, no mess, easy as pie. Instead of one big plug on the side, you have to remove 4 10mm's from the top shifter. All can be easily accessed once the shift boot is moved.

[studum]

Probably someone like me owned it. . :) I've only used the factory fill plug once or twice. That was long before I found the easy way to replace tranny and t-case juice. I now just pull the shifter and dump the correct amount of fluid down the hole from inside the cab, no lying on my back, no drips, no mess, easy as pie. Instead of one big plug on the side, you have to remove 4 10mm's from the top shifter. All can be easily accessed once the shift boot is moved.

Does that work for Sidekicks too?