Transfer case filler plug thread

[BenDover]

Hi All,

I just got my gearbox and clutch all back together and tail shafts on, undid the transfer case filler plug to fill it with oil and the thread for the case came out with the bolt!!! And no the bolt was not cross threaded or anything because the thread on it is perfect.

Why this happened isnt as important as how I should fix this.

Do I get a mobile mechanic to come and remove the rear case for the transfer case and take it to get re-drilled/threaded or should I remove it myself?

I've never done it before and have no idea as what I am going to encounter if I do it myself. Has anyone else done it and can you give me some advise?

Cheers

[Goatse.AJ]

An unfortunately common problem.

Probably easier to take the whole case off. Putting it back on, you'll need some gasket goo or similar.

You should be able to prise it off the back of the gearbox without too much trouble. That way you can take it to somebody to re-tap, OR chase up a second-hand case from somewhere and replace the whole thing.

[BenDover]

Thanks for the reply. So you think take the WHOLE transfer case off? I was actually meaning just take the rear section of the transfer case off. The panel that has the filler/drain plugs on it. Make sense?

When I was looking at it it looked like you could unscrew about 10 or so bolts and that panel would come off. I figured that panel would have to come off anyway as when it gets re-tapped the metal bits would get inside the case.

Hope I havent confused you...

[MightyMouse]

I think its a Daihatsu thing, stripped plugs are very common.

Before changing transfers I Teflon taped mine, screwed it back and gave it a generous coat of silicone. Didn't look very pretty but kept the oil in.

Not certain its worth all the effort of a proper fix but that's up to you.....

[Goatse.AJ]

I think you'll find it easier to just remove the whole transfer case off the back off the gearbox.

[BenDover]

Ok made some calls today and there is a guy who specializes in re-threading. He's going to do it for $88. No need to remove the case either so im happy. He said with the case full of oil the oil dribbling out will remove most of the shavings and i'll flush the case afterwards too to remove any remnants. Should be fine I think.