Outer Limits 4x4 Board

I need help removing a VERY stripped tranfer case filler plug on my hj60.Recently purchased car and have a desire to change oil.(not even sure if it's got oil in it)

what tools and/or skills do you have available?

if you have a MIG the easiest way is to weld a nut to the plug - pick a good sized nut that you can weld through the middle of onto the plug.

if you have a hacksaw and endless patience you can cut a slot into the plug and use a big screwdriver with a shifter on it. no guarantee.

if you have a grinder or even a file you can make new flats on the plug and put a spanner, socket or shifter on it.

you could try drilling it out and using a stud extractor however swarf will probably end up inside the tcase. bad.

you could try just bashing a chisel in the right place to loosen it.

bash on a slightly too small socket.

make sure you use a 6 point socket.

there are probably more options.

Due to the long range fuel tank being about 10cm from the plug access is somewhat limited.No mig.

Do you mean the thread on the plug is stripped or the filler plug bolt head is rounded?

Good point,i mean the head is VERY rounded.It seems to be some kind of softish metal,perhaps alloy.The best option maybe to try and weld/mig some kind of nut to it,however i'm not equiped to such a job.

vanners wrote:Due to the long range fuel tank being about 10cm from the plug access is somewhat limited.No mig.

file and patience. put two new flats on the plug and get the vice grips on it.

vanners wrote:Good point,i mean the head is VERY rounded.It seems to be some kind of softish metal,perhaps alloy.The best option maybe to try and weld/mig some kind of nut to it,however i'm not equiped to such a job.

If you get a $20 SuperCrap 100mm grinder and a 1.5mm cutting disk for stainless steel, you can cut a slot in the bolt head.

The other option is 24" plumbers stilsons. They have a good bight on them and great leverage.

v6hilux wrote:

vanners wrote:Good point,i mean the head is VERY rounded.It seems to be some kind of softish metal,perhaps alloy.The best option maybe to try and weld/mig some kind of nut to it,however i'm not equiped to such a job.

If you get a $20 SuperCrap 100mm grinder and a 1.5mm cutting disk for stainless steel, you can cut a slot in the bolt head.

The other option is 24" plumbers stilsons. They have a good bight on them and great leverage.

vanners wrote:Due to the long range fuel tank being about 10cm from the plug access is somewhat limited.No mig.

Hammer and chisel would be my choice. I would say it has an alloy plug in it. If your going to buy a new one make sure its a steel one or go to a wreckers and grab one out of a toyota diff housing as they are all steel and fit the gearbox as well.

Can you weld onto soft alloy?If so i think welding a nut on and then using a spanner would seem the way to go.ive had a set of locking pilers on it with good grip but it just keeps chewing the plug(whats left of it)away.The plumbers wrench has done the same.It seems very tight.

vanners wrote:Can you weld onto soft alloy?If so i think welding a nut on and then using a spanner would seem the way to go.ive had a set of locking pilers on it with good grip but it just keeps chewing the plug(whats left of it)away.The plumbers wrench has done the same.It seems very tight.

I know how soft those plugs are and you will really struggle to weld anything to it. If its that tight then your going to need to give it some shock treatment. I think you will be suprised how easy it comes off with a hammer and chisel.

just remember your trying to turn it not cut it off with a hammer and chisel

Thanks for that,its just sometimes the simple things in life give you the most grive.I Will attempt the hammer and chisel method,just getting somewhat concerned cause there isn;t much of the plug head to play with.

You really need to post a a pic os this sucker!

i've started filling to flats either side,with the plan of using an open ended spanner,a givingthe spanner a hit with a hammer to try and crack the seal.

Was the plug allready stripped when you first tried to undo it?

All is well that ends well!After getting somewhat wet a little abit of swearing,she is out>>>>>Obivously to hard for previous owner,as he had created a little monster.i ended up filling it to make a square and got a 19mm open end spanner and hit it.Have not yet dropped the drain plug but am quite sure it is empty.Think i may run a level hose from the gear box as an insurance.Thanks heaps for all your feedback.Gotta love old trucks and the joy of success.(regardless of its size and importance).I wil try for some photo,s.

Giddy up

RUFF wrote:Was the plug allready stripped when you first tried to undo it?

of course it was. only Previous Owners have "Teh Skillz of Teh Fisted Hex". ask anyone - they have never Done It Themselves, it was always 'The Previous Owner - he was a Butcher'.

Well that's me story and i'm sticking to it!!