I was under my Jeep yesterday checking the front and rear diff fluid levels. I decided I might as well check the transfer case as well. I finally located the check/fill plug and the drain plug and ran into a problem. They are both these huge flat hex head type bolts. Anyone else run into this? What did you use to get them out and what did you replace them with?


Thanks

 

I use a big cresent and make sure it is tight and apply pressure slowly,it will come off.

 

I was going to try that next, just worried about stripping the edges off. I love my Jeep but why do they have to use such strange sizes for their check/fill plugs.

the one on my trans is 5/16 square...lucky with the diffs its plain old 3/8 so my socket head fits in there.

 

Drained one on one of my junkers, today. I used a big socket. Think it was a 32mm one.

It sure is a bizzare size.

 

Looks like I have yet MORE tools to buy. Oh well. better than paying a mechanic to do it for me I guess.

 

For the 5/16" square drive plugs (you'll find them on the Peugeot BA-10/5 transmission, some transfer cases, and often the engine block drain plug,) you can make a tool fairly easily - vice buying one for $$$.

Go to the hardware store, and pick up a cheap-O 5/16" or 8m/m hex key (they're the same size to within a few thousandths.) Get out your grinder, and slowly grind away opposite corners until the measurment across the two corners is about the same as across the flats. You won't need to grind much, and it only takes a couple of minutes.

I usually do this on the short arm of the wrench. You can then use it to break those plugs loose. I am informed that the block drain is a 3/8" NPT, but I've not had a chance to verify this. If it is, go get a standard 3/8" NPT plug at the hardware store (brass won't seize, FYI) and replace it with something standard.

Or, you could do what I plan to do - I want to add a street ELL and a valve, so I can have it drain straight down without having to remove anything - just turn a handle and drain.

 

Ahh a grinder, something else to buy. One day Ill end up with a somewhat respectable set of tools to work with. I need a grinder/cutoff wheel, breaker bar.....and on and on and on the list goes.

 

they're allen heads, 10mm

 

The square plug is a 10mm allen?

 

I'm a po'mo'fo' so i use a 12" pipewrench. works great.

 

I used a cresent wrench lol Worked great. Then I bought a socket to fit and that worked great to lol

 

no. some transfer case drain/fill plugs are allen head (hex head) instead of a socket size.

if its Allen/Hex then its 10mm.

if its a bolt for a socket then its a 30mm.



at least for the np231, I've never seen the 242.

this link explains: http://4x4xplor.com/trannyservice.html

 

My 242 and 231 look the exact same. same size drain/fill plugs

 

You don't have a grinder yet?