Stripped Transfer Case Fill Plug

I’m wanting to replace the fluid in the transfer case and come to find out the fill plug is completely stripped. I’ve read that I might be able to fill it from the top of the shifter but don’t know the exact process I should be doing it.
Where do I put the fluid exactly?

 

I feel like there should be enough room there for vice grips or a pipe wrench or something. You pretty much need to remove the fill plug to determine what the level should be as far as I know.

Transfer case fluid usually looks nearly new after many, many miles if that makes you feel any better about leaving it be for now.

 

Not sure where you heard that, but I don't think so. Could be wrong. Please tell me you haven't already drained the fluid.

 

I'm surprised you can't get it off since it doesn't look that rounded.

When in doubt, weld a socket to the plug.

 

I'm also not a fan of 12 point sockets for removing anything that is stuck tight or even beginning to round. I prefer 6 point impacts. Easier to hold on there than a breaker bar and less likely to slip and round it even more.

 

That should come out, if needed enlist a gearhead buddy to help. I always remove the fill plug first, just for these situations, then if you can't get it out first, you still have juice in the box.

 

SOP.

 

Man, if I had a dollar for every time I'd warned people about stripping the TC fill/drain plugs

Sorry to see you're dealing with this. , and I wish I had some good suggestions on a solve.

 

Does RocketSocket make an extractor socket that big? Anyway, just buy one at Harbor Freight or somewhere online. It should be able to come free easily.

You may be able to use a lug nut extractor in the right size.

 

chisel and a hammer...go Moses on its ass

 

Is there room to use a hand impact and swing a hammer?

$26 Toolwiz 1/2" Hand Impact Screwdriver Set - 14 Pcs, Reversible Manual Impact Driver with S2 Steel Screwdriver Bits for Disengage Rusted Fasteners or Frozen Bolts

https://www.amazon.com/Toolwiz-Hand..._csd=d2lkZ2V0TmFtZT1zcF9waG9uZV9zZWFyY2hfYXRm

 

I think I misunderstood this at first. Fill plug is stripped, as in, it's just spinning instead of coming out.

I'd be worried about cracking the case if using hammers and chisels and such. With alloy, you can usually apply up/out ward pressure on the fastener and get it to cut new threads. But looking at the pics, it look like you may've already tried that? If you can manage to get leverage underneath the lip of the head, you could use that to push up.

If it were me, I'd probably be tempted to drill the fastener about 1/2" deep in the center of the fill plug head and tap it, just so I could thread a bolt into the plug (insert Xzibit meme) and lift up/out using that bolt while I have a box wrench on the plug.

 

I took it as the head was rounded off not the threads stripped. Maybe the OP can elaborate.

 

I'm pretty sure it's rounded, picture tells the tale.

 

I took mine to my favorite shop and had them weld a nut onto the plug. While it was hot from the welding, they put an impact on it and got it loose. Made my life a lot easier for under $20.

 

It came off with a little heat, penetrating oil and a socket that was small enough to hammer on. Thank you for all the input.