Transfer case filler plug

[david7307]

I am going to check the oil in my transfer case this week , and from memory of last time, its a hard job getting filler plug out, i used a half inch drive head to remove it , can you replace plug with a standard bolt like plug and just use a spanner to undo it ,and if so what size of thread is it

[Pippin]

I am going to check the oil in my transfer case this week , and from memory of last time, its a hard job getting filler plug out, i used a half inch drive head to remove it , can you replace plug with a standard bolt like plug and just use a spanner to undo it ,and if so what size of thread is it I did mine last week with no problems, I don't think you will be making it any easier with a bolt. Nick

[ballbag]

Use a 5/8” extention bar and ratchet with 1/2” adaptor on the end of it. Easier to get it square than using 1/2” gear[emoji106]

[bee utey]

Pretty sure it's 3/4" BSP, any plumbing shop should have something suitable in brass. But I bet the original plug would seal better as it's made for the job.

[AndrewMilne]

I am going to check the oil in my transfer case this week , and from memory of last time, its a hard job getting filler plug out, i used a half inch drive head to remove it , can you replace plug with a standard bolt like plug and just use a spanner to undo it ,and if so what size of thread is it

Hi David,

I have also had difficulty with this (every time) - my transmission brake housing gets right in the way.

In contrast to the 5/8 inch idea, I think a 1/2 inch sq drive universal with male ending works pretty well.

Just put the 1/2 inch male ending into the square recess in the plug.

Cheers,
Andrew

[mrb505]

Use a 5/8” extention bar and ratchet with 1/2” adaptor on the end of it. Easier to get it square than using 1/2” gear[emoji106]

I’m guessing you meant 3/8 not 5/8 but anyway that’s easiest way I’ve found too

[rick130]

Just use a long 1/2" wobble drive, gets you past the parking brake drum easily.

[rangieman]

Just use a long 1/2" wobble drive, gets you past the parking brake drum easily.
x2 [thumbsupbig]

[AK83]

I think the brass diff filler plugs are the same.
Search for discovery brass diff plug .. or something similar you get many hits.
Same brass pugs are used on the D1 radiators and on some of the D1 engine bleeders.
They're a better replacement plug type for the plastic ones LR fitted originally.

Some D1's use those 1/2" drive filler plugs on the diffs too.

Can't remember the size of the hex head tho .. something like 7/8ths or similarly large so if you go that way, just make sure you have a ring spanner to suit.

[ballbag]

I’m guessing you meant 3/8 not 5/8 but anyway that’s easiest way I’ve found too

Yeah, that’d be the one.

I often wonder whether the designers/engineers were really clever and designed things like this with just enough room, or did they not think if it and got lucky that there just happened to be enough. 🧐

[Tinggu]

I've never been able to get 1/2" ratchet or extension onto the plug. What works for me is 1/2" square bit of bar that I push into the plug, then use a 1/2" spanner to turn it.

[david7307]

I've never been able to get 1/2" ratchet or extension onto the plug. What works for me is 1/2" square bit of bar that I push into the plug, then use a 1/2" spanner to turn it.


I had thought of this and after reading that some one had done it .
worked great about 25mm of 1/2 in square , easy [bigrolf][thumbsupbig]

[rick130]

I've never been able to get 1/2" ratchet or extension onto the plug. What works for me is 1/2" square bit of bar that I push into the plug, then use a 1/2" spanner to turn it.
I've never been able to get 1/2" ratchet or extension onto the plug. What works for me is 1/2" square bit of bar that I push into the plug, then use a 1/2" spanner to turn it.


I had thought of this and after reading that some one had done it .
worked great about 25mm of 1/2 in square , easy [bigrolf][thumbsupbig]But a 1/2" wobble drive extension gets past the drum and you can use it in so many other spots.

They are really good bits of kit, I have a selection in 1/4, 3/8 and 1/2" drive

[Tinggu]

Wot's a wobble drive? I have a little 1/2" unijoint that is quite useful here and there, but not for this job. Wobble drive? Hmmm....

[bee utey]

Wot's a wobble drive? I have a little 1/2" unijoint that is quite useful here and there, but not for this job. Wobble drive? Hmmm....

It's like a standard 1/2" drive except ground away to allow drive at an angle. Example:

3 Piece 1/2" Drive Wobble Extension Bat Set Ratchet Socket | eBay (https://www.ebay.com.au/itm/3-Piece-1-2-Drive-Wobble-Extension-Bat-Set-Ratchet-Socket/251414091939?hash=item3a897298a3%3Ag%3A4wgAAOxyRhB S1rNV&_sacat=0&_nkw=wobble+drive+socket+extension&_from=R40&rt=nc&_trksid=m570.l1313)

[DiscoClax]

Wobble drives, like ball-end Allen keys, are bloody brilliant bits of kit. I wouldn't be without them :) Not quite as strong though, so you need to temper your enthusiasm...

[Tinggu]

Cool! I can see how that would work. I'll be ordering the kit.Thanks,
Pete