Just bought my first Jeep earlier today. '98 XJ with 4.0L and automatic.

My 231 transfer case has the "inset" 10mm hex fill and drain plugs. I have not tried loosening them but they look very rusty. I know the case is aluminum and the plugs are steel. Not sure if it will do any good but I will soak them with PB Blaster penetrant. Afraid of rounding out the hex and/or stripping out the aluminum. Assuming I can get them out I will replace with the Napa external plugs.

I will try to remove the fill plug first. Any tips or tricks about how to get them out if they are stuck? Do they typically come out OK if the face of the plug is rusty or are they prone to freezing into the case?

Thx.

 

If the jippy lube dude had at it they are already stripped out, just weld a nut on it.

 

spray a dab of PB Blaster on them. use a small screw driver and scrape all the just you can out of the holes. clean them out the best you can. Take the short end of the 10mm allen wrench and make sure it goes the entire way into the plug. Then use a wrench or a cheater pipe for leverage and give it a little bit of a turn to the right(tightening it slightly) then give her a cranking to the left.

I know it can be scary both of mine were VERY tight but both came out no problem. Luckily they were only rounded out about 1/8th of the way down the hole from someone in the past not having the allen in the entire way. There was still plenty left to get a good bite

 

They'll probably come out if there's fluid on the other side. They came out of my TC from 1987 in the rust belt without difficulty. Just make sure you're using the right size tool and go slow. PB Blaster is you're best friend. Spray on a few days ahead and keep adding every night until you're ready to take them off. Also, I would think it better to have the fluid inside warm before doing it so drive it around a bit first.

 

thanks for the replies guys. PB Blast, scrape, fully seat the hex, smidgin of tightening and give it a whirl. Got it.

 

Good work!

 

I'm glad you realize they are 10mm. Too many people think they are 3/8 and not only strip the hex but expand the plug at the same time! That makes them a B**** to remove! Aluminum expands more than steel so the warming it up is a great idea. You can try a mixture of ATF and Acetone (nail polish remover) as a penetrating oil. As far as I'm concerned it's about the best there is! If I were you, I'd get new cadmium plated plugs.

 

Glad to report that the plugs "moved". I hit them with PB Blast. Used a "dental pick" tool to scrape around the plug as well as clean out the hex. Blasted WD40 into the head to flush the debris I picked out. Tapped the 10mm hex into the plugs. I messed up and bought a 3/8" drive 10mm hex but was some serious grunt I was able to get both plugs to move. I didn't remove them since I ordered the external plugs and they'll be on Tuesday. Once I have the new plugs in hand I'll change the fluid. Ordered my Bushwacker flat fender flares and shackle relocation kit today so I'll be spending some time workin' the jeep over the next couple of weeks.

 

Thinking that might not be an option. Came across that idea last year. Read Post# 8 and 9.

https://www.cherokeeforum.com/f2/tra...ripped-233845/