After reading a thread a while back about GL-5 fluid in transmissions, I got some GL-4 and figured to change the fluid in the transmission, just in case, and the transfer case while I was at it.  All went well until I tried to remove the fill plug on the transfer case.  The hole has been buggered up so the tool won't work.  I was about to go after it with a hammer and chisel when I had another idea.  I can't tell from the service manual whether it will work or not, so I figured I would consult with the experts before trying.  If I remove the gearshift and pour the fluid in there, will it go down into the case?  Seems it should, but I'd rather be sure before starting.  Thanx in advance.

yes, that ill work - providing that your shfiter sheet is in good condition.  If the sheet  is all torn up, you'll rinse the pieces down into the t-case.

Be sure to measure out the correct amount per the FSM or owner's manual when filling.

Thanks for the quick reply. 

It seems there is no such thing as a quick task.  Something always happens to screw it up.  Oh well, if I got it done too quickly, the warden would find something else for me to do.

Try some heat, heat gun or torch on the casing around the plug. Mine was stuck and rounded out also. Put some heat on it and it came out "rather easily".

Someone may have put the wrong Lock-Tite on the threads.  Heat will normally loosen the plug if that is the case.  Tap the flats with a punch, or make grooves in the plug to tap upon.

My G-V has enough of the plug sticking out of the casing to allow a Vise-grip to lock on to the plug.  Heat it first though.

Tom

Good idea, tjwolf.  I think I will borrow the warden's hair dryer.  I would be a bit leery of using a propane or acetylene torch under the car, with as much grease as there is in the area.

As an aside, I did a google search for ideas.  There were many suggestions to loosen the fill plug before draining the oil.  The idea was to avoid this situation.  I had thought about it before I started, but thought I had had it off a year or so ago, so it wouldn't be a problem.  Guess I remembered incorrectly.  Someone said that the memory is the second thing to go--I forgot what was first.

If I remove the gearshift and pour the fluid in there, will it go down into the case?  Seems it should, but I'd rather be sure before starting.  Thanx in advance.

Samurai=yes.
Trackick=no.

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Samurai=yes.
Trackick=no.

After I got the reply from Ack, I went out and tried it.  It took all the fluid I poured into it and nothing ran out on the ground.  FWIW, I tried the same thing with the transmission, and that did not work.  Maybe you misunderstood and were thinking my question was about the tranny instead of the transfer case?

It turns out I had the same problem getting the fill plug out of the transmission.  I resorted to some brute force and ingenuity and got that one out.  I won't have that problem again--I welded a bolt into the recess.  Now all I need is a 14mm socket to remove it.  When I find the time, I will do the same with the other fill plug and maybe with the drain plugs.  The transmission plug is on the bottom, but it is high enough that it is not likely to get caught on anything.  The transfer case drain is on the back of the case, so it won't get in the way of anything.  The only concern would be the effect on the magnets in the drain plugs from the heat of welding.  Since the car has 115k miles on it, there probably won't be much more iron worn off the gears for the magnet to catch, anyway.

Quote from: Skyhiranger on April 21, 2009, 06:12:51 PM

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Samurai=yes.
Trackick=no.

After I got the reply from Ack, I went out and tried it.  It took all the fluid I poured into it and nothing ran out on the ground.  FWIW, I tried the same thing with the transmission, and that did not work.  Maybe you misunderstood and were thinking my question was about the tranny instead of the transfer case?

Oops, yep, I thought you were asking about trannys, not tcases.