Perminant Transfer Case filler plug?

bmwhacker · Nov 19, 2018

Good lord.
Minor seepage on plate on transfer case. Thought I'd better confirm oil level right away.
Simply attempted to pull transfer case filler / check plug and man is it TIGHT!
Looks like a PO used some silicone around it....hopefully not "Lok-Tite".
I'm afraid I'm going to break something. Using 16" breaker bar and that sucker won't budge.
Maybe driving some highway miles might heat up case enough for some expansion?....Then give it a shot?
The plug has obviously not been removed for a long time....definitely don't want to break / overpower anything.
Any other suggestions?

mr glee · Nov 20, 2018

Try tapping the bar while under load with a hammer or tap the socket end into the plug while under load just be patient may take some work to get it to move.

Colthebrummie · Nov 20, 2018

Give the area around the filler plug a good clean then apply some heat with a blowtorch.

Col

sierrafery · Nov 20, 2018

If heat doesnt work try the other way around https://www.halfords.com/motoring/p...atment/halfords-shock-unlock-spray-400ml-2017

Colthebrummie · Nov 20, 2018

sierrafery said:
If heat doesnt work try the other way around https://www.halfords.com/motoring/p...atment/halfords-shock-unlock-spray-400ml-2017

I've never seen that spray before, might be worth a go for less than a fiver. Just don't spray it on straight after trying with a blowtorch, let everything cool naturally first.

Col

bmwhacker · Nov 20, 2018

Good thoughts....didn't think of a little "shock" treatment.
Been thinking....maybe this sounds a bit "U.S. redneck" but:
Since the plug sits vertical, I'm going to silicone a small "cup" over the fill plug (cut from a plastic jug handle?).
The cup should retain PB Blaster / penetrating oil so the entire plug area can be soaked in the oil.
I don't think spraying directly on the plug is going to penetrate enough.
Maybe after doing that I can heat it up and give it another try.

jamesmartin · Nov 20, 2018

bmwhacker said:
Good lord.
Minor seepage on plate on transfer case. Thought I'd better confirm oil level right away.
Simply attempted to pull transfer case filler / check plug and man is it TIGHT!
Looks like a PO used some silicone around it....hopefully not "Lok-Tite".
I'm afraid I'm going to break something. Using 16" breaker bar and that sucker won't budge.
Maybe driving some highway miles might heat up case enough for some expansion?....Then give it a shot?
The plug has obviously not been removed for a long time....definitely don't want to break / overpower anything.
Any other suggestions?

use the breaker bar and your foot , i use a longer bar than that on some

mr glee · Nov 20, 2018

Funny enough this is what advice I was given by a American car forum to get the brake retaining bolts off a cougar after breaking bars and bits .redneck maybe but it worked.

dieseldog69 · Nov 20, 2018

I've used a 2 foot breaker bar and brute force before now

Henry_b · Nov 20, 2018

Ah put ya back into it ya wimp

Gazbo · Nov 22, 2018

bmwhacker said:
Good lord.
Minor seepage on plate on transfer case. Thought I'd better confirm oil level right away.
Simply attempted to pull transfer case filler / check plug and man is it TIGHT!
Looks like a PO used some silicone around it....hopefully not "Lok-Tite".
I'm afraid I'm going to break something. Using 16" breaker bar and that sucker won't budge.
Maybe driving some highway miles might heat up case enough for some expansion?....Then give it a shot?
The plug has obviously not been removed for a long time....definitely don't want to break / overpower anything.
Any other suggestions?

Those plugs are tapered thread, once it has "cracked" from tight it should come out easily, sounds as if it may have had some sort of loctite or other thread sealer used on it, bearing in mind some of the sealant materials have the same anerobic properties as the proper loctite thread locker.
Over tightening of these taper type plugs can in extreme cases cause cracking of the alloy case around the plug, a turn of thread tape around the plug is usually good enough to seal the potential leaking, but you should avoid overtightening the plug, usually on my Disco I simply use the standard length Rachet handle from my socket set.
Unfortunately the oil you're seeing on the bottom of the transfer will more than likely be coming from the intermediate shaft "o" ring seals, the most common and usual suspect, a job that cannot be done without removing the transfer case from the gearbox.

bmwhacker · Nov 25, 2018

Yup....I decided to "put my purse down" and get a bit "western" with it.
She finally cracked loose. Transfer case oil level just a bit low, nothing to worry about.
Oil is definitely "seeping" from the large inspection plate. Very minor, maybe a drop a day.
Reset plug with a bit of anti-seize and didn't get western tightening it.
I have some physical limitations so "getting western" is a bit hard to do these days.
I'll leave the "wimp'in" to you blokes.

bmwhacker · Nov 25, 2018

Yup...."put my purse down" and got a bit western on that bitch....she finally broke loose.
Oil level only down a little, nothing serious.
Definitely seeping from the lower edge of inspection plate seal (or gasket?...I don't know what lives there)
Very minor seep and I have lots of gear lube...let'er f&%king seep.

Took the rig out into some easy desert areas yesterday. Nothing technical but some rocky rough stuff.
I suppose you Englanders mainly drive around in the rain / moss / mold and get stuck in bogs? ….lol

Went out to an old 1890's ghost town / mining area near the California border.

Gazbo · Nov 25, 2018

Oy!, Ease up, some of us don't live in Englington..........

Perminant Transfer Case filler plug?

bmwhacker

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mr glee

Active Member

Colthebrummie

Well-Known Member

sierrafery

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Colthebrummie

Well-Known Member

bmwhacker

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jamesmartin

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mr glee

Active Member

dieseldog69

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Henry_b

Think outside, no box required.

Gazbo

Well-Known Member

bmwhacker

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bmwhacker

Member

Gazbo

Well-Known Member

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