Outer Limits 4x4 Board

Ok so tried to fit my parttime kit today, should have payed someone. I cant unbolt the 12 bolts of the bit in the transfer case that needs to be replaced. Put an extension bar on and everything, tried compressor and still cant get them off, no corrosion. Has anyone thats done this mod encountered same problem and if so how did you get the buggers off.

Also same issue with diff oil filler plugs cant get them off and have rounded one trying.

Any help would be great, Cheers.

How long was your extension bar?

The diff filler plugs can be troublesome complicated by a poor fitting spanner/socket. Best now to go for a big pair of multi-grips or vise-grips. If that fails, a cold chisel and hammer. You'll need to replace the plug sometime [naturally].

Let us know how you get on...

Cheers

Have already tried multi grips an there a no go. Extension bar is the longest that i can fit under the car. How does the chisel work cause if i split it in half how do i get the tread out.

when i did my parttime kit i got those bolts off with a ratchet gun off the air compressor came off pretty easy just make sure tank is full before trying as for sump plugs you could try a cheap smaller socket force it on then use extension bar. I had to use a breaker bar about 30cm long then get someone to hold it on then hit bar with mallet the shock should free it up.

little tip
when trying to undo a tight bolt /nut always tighten it up a little 1st this breaks the hold ..making it easyer to undo ...works well on heads and mains
an old retired mechanic told me this and it works a treat

If you have striped the head of the bolt use an old screw driver or chisel to hit the edge of the bolt making it turn. You may need to hit the bolt straight on to make a bur.
This is always been the last resort for me as it damages tools and is quite frustrating to do, BUT WORKS.

Best thing for the diff plugs is an impact socket coz its only hex and doesn't have all the extra notches so won't round the edges. Same prob with mine getting em out. Welded a short bolt to it and the heat helped amd came out easy. Buy the after market ones and you will never have these probs.

Tried them all. No go. Bolt is too soft. Even had a go with a thread remover. Will be getting someone out wednesday, apparently is an expert it removing nuts an repairing threads so might have to drill it out and redo the thread. Heard bout the hex socket today. I thought a 12 point was better, guess i was wrong. Spewn as im leaving for bourke next monday an repairing car is in hundred pieces.

Did you try a bit of heat on the diff plugs, or moreso the ring section they actually thread into. Obviously heat around the fule tank and near oils needs to be done with care bbut often with bolts I know are stuck pretty tight I heat the surrounding area primarily to hopefully expand the thread and then spray WD40 or similar on the bolt to hopefully cool it quickly and shock break the bond. Water works or course but it's often benificial to try and get a bit of the penetrating oil in at the same time. WD will smoke pretty bad and if the surface is hot enough and you put enoough on it will fire up but easily controllable as you are not pooring gobs of the stuff on there.

Someone said tighen the bolts a smidge first too to help break the bond and same is said for giving it a whack with the hammer first too to try and break any bond.

Abviously all these tips need to be mindful of what component you are talking about, what the parent material is and with heat any fire concerns but a reasonably small torch flame can be handy for some of the areas of more concern. I'm not talking the Oxy set here for example but some of the nice compact gas flames with small but powerful tips.

to get the plugs out of mine when i bought it i cut a groove across the head, like it was going to take a flat head screw driver. I made it wide enough to fit a lawnmower blade in and then turned it with a shifter.

- later replaced the plugs with longer hex head plugs.

-Dave.

my plugs are really shallow heads will be getting new ones from local bolt shop. No more probs then. Those bolts are the stupidest design ive seen. They're really soft and round easily.

Ok so a six point socket was the go, unfortunately i used a 12 point first and rounded 2 in the transfer case but with a bit of heat and these special sockets that i got from bunnings that cut into the head as you undo done the trick. As for the sump plugs, alot of heat an the cold chisel was all that worked. needless to say both were replaced with big mothers so i never have that problem again. I will also be investing in a quality set of six point sockets to replace all my 12 points.

Ps trip was awesome and thanks to everyone for their help and inputs,
Cheers, Nathan

I wouldn't go replacing sockets. I think most impact sets are hex style. Fourby shops sell replacement plugs as kits for diffs and gear box/transfer. I've got just one good hex socket 24mm in truck to undo these.

onther option is to try and get a bolt with a 1/2 inch socket recesed into like dare i say it (nissans) have then all you need to do is clean the mud out and use a standard 1/2 inch breaker bar or ratchet

Nissans are a tapered thread though so they seal by tightening on the thread itself, toyotas rely on steel and aluminium washers so that type of plug is out