Outer Limits 4x4 Board

Today when i tried to get the transfer case oil filler plug off the bolt just rounded off and everything else i tried to get it off didnt work. Any ideas on how i could get the bolt off?. And also, the bolt is really skinny, like 1/4 of an inch, is this right or should it be a bit bigger?

couple of ways to get it off:

1> tack weld a bolt to it so you can use a spanner/socket to wrench on the bolt.

2> carefully use a cold chisel and hammer to slowly knock it in the direction required. this will require the plug bolt to be replaced but by the sounds of things it will anyway.


Alternatively you can drain all the oil out and fill it from the hole where the shifter goes into the trasnfer case. Refer to a service manual for the actual amount of fliud. From memory it's about 800-900ml.

It's easier to buy one of those 1ltr top up oil things from supercheap that have the long rubber easy pour spout on them. you can connect a bit of garden hose to the end of that to make it easier to get the fluid into the xfer and not all over your driveway.


hope this helps.


Where all else fails you can pay someone to remove the stripped filler plug and isntall a new one.

Thanks for that help. I filled it from where the shifter go into the case and it worked. THought i was screwed for a while there.