Transfer case problem need suggestions please

[Robby Avery]

So I have slight problem being I work at a gm dealer i was able correct one problem and suck the old fluid out with special machine we have at work and put new fluid in but not the other my wife's lb7 in my sig is the one I asking about I need suggestions on how to get the lower drain plug out last time I changed the transfer case fluid I didn't think about it and ran the aluminum drain plug all the way up flush being that's all I've done since I've owned the truck since 2009 and didn't think about the alumnium oxidation which siezed it in place now and when I went to removed it I used a 18mm wrench 6 point and it rounded off what is the best way to remove it so I don't have to purchase a new rear case half I thought about welding a nut to it or using an extracter but the aluminum is soft and I'm kinda at a lost as what to try next I even tried channel lock and locking pliers as well as air hammer with chisel to try and back it out with no luck anyone ever have this problem if so what is the best solution to fix the said problem thanks in advance

 

[Robby Avery]

59 views no response I need help here please thanks in advance

 

[Yellow Jacket]

Is the plug aluminum too? I would weld to it, the heat will help free up the oxidation too.

 

[02CCSB]

The case is magnesium, the plug is aluminum and its pipe thread...why in the world would you "run it all the way in"? I mean it even says "do not use impact gun on drain or fill plugs" right on the damn case. Anyways, get the truck in the air, get a good pair of vice grips and go for it I guess.

 

[Hot COCOAL]

Robby, have you tried to heat the case, around the plug?
Welding a nut to the plug is going to be your best bet...

You could try to drill and tap the plug with a reverse threaded bolt and see if it will turn the plug out...but that isn't going to be too fun

 

[Robby Avery]

Thanks so much no impact gun was used just a ratchet and 18mm 6 point socket I figured welding on a nut on would be the best option and if that doesn't work I'll have to try other methods thanks for all the info so far I really appreciate :thumb:

 

[Chevy1925]

Thanks so much no impact gun was used just a ratchet and 18mm 6 point socket I figured welding on a nut on would be the best option and if that doesn't work I'll have to try other methods thanks for all the info so far I really appreciate :thumb:

if welding doesnt work, the last thing you can do is pull the case half, drill the plug out just smaller than the threads and retap the plug hole to clean out the old threads. or drill it and helicoil it but i dont think they make NPT style ones. you would have to use a bolt and sealing washer

personally, id pull the case half, heat that sucker up good after welding a nut on it and see if it comes out. remember, you are working with some pretty soft metals so its very likely you can pull the threads out of the case

 

[lil bleur]

I'd try a Turbo Socket and if that don't work do what the other guys are saying...weld a nut on.

 

[Alisobob]

http://www.craftsman.com/craftsman-10-pc-damaged-bolt-nut-remover-set-low/p-00952166000P

These things are lifesavers.....

 

[NC-smokinlmm]

If you got the old fluid out and refilled it why are you worried about it?

 

[THEFERMANATOR]

Just remember, the case half is aluminum, and magnesium is extremely flammable. Once it starts to burn, it tends to not stop as it is its own oxydizer. So I wouldn't chance welding on it in the truck. Otherwise, take the fill plug out, get you a suction pump, and fish a tube down to the bottom and suck the old fluid out.

 

[holyshitbatman]

Idk if its just me but if u can suck it out sounds like a solution fill it up and call it done for now order some merchant plugs and deal with it next change just be ready for it or just suck and fill in that truck .have u tried a small pipe wrench they bite like crazy if u got enough of a nub showing.

 

[Robby Avery]

I did the suction method at work through the fill plug hole I just want to now in the event that I don't have access to a suction pump I can do it manually you know I'll look in to the socket extracter I have a set just not one low pro like that set only other option is to try extracter small pipe wrench then pull case down and try heat and welding nut on to see if i can remove it hopefully I'll be able to :thumb:

 

[sawmilldmax]

I've had a little luck with left-handed drill bits in a variable speed drill, notice the key word is little.