Transfer Case Fill Plug Stuck

(this is where removing it earlier comes into play, if it is stuck and stripped, you now have no fluid in the rear and no way of adding it). I am trying to remove it with an easy-out and while drilling a pilot hole for a bigger bit I broke the bit and it fell into the TC. Remove the drain plug, and watch the transfer case fluid pour out. It was supplied in many GM, Ford, International and Dodge full-size trucks. I will be getting a used transfer case and have a new seal put on it and swapped out. Does anyone know what size bit will fit that and where i can. Replace a transfer case shift motor. Both take a 3/8" drive socket holder like a ratchet or bar. I ordered a new one direct from ford and got it the other day. You found the transfer case drain, and that's the fill plug just above and to the right in the picture behind that bracket. com has all the parts and accessories you need to keep you adventure vehicle slinging mud with the best of them. New question, Will the transmission fill plug part number 5140A fit?. 44 Drain Plug - Magnetic 1 1250-E-473 3/4"-14 NPT square socket 45 Plug 4 P-26 3/8"-18 NPT square socket 46 Fill Plug 1 P-212 3/4"-14 NPT square socket 47 Capscrew 6 MS208045-1 M8 x 1. drain the old, fill it up with the right ATF until it spills out and plug it back up. I had very little mung on the magnet from the drain plug on the transmission. I just did all fluids over the weekend and had the same problems, on the transfer case my drain plug was a hex bolt also, the aluminum to steel corroded pretty bad, I soaked with pb blaster used a small torch and with a hand 3/8 impact driver gave a few light taps with a hammer and it came loose with out further damage, same with the rear end drain plug. The job of the spark plug is to ignite fuel in the combustion chamber of the engine with an electric current. Dealer had to replace the transfer case servo motor with a new updated design. While the truck was still on the stands I used my same 5gal. When I switch to 4H, the amount of play in the driveshaft is about the same although it "feels" a little different. but in the picture im. 0L 6-cyl Engine. Then when you're ready to refill, you put that plug back in, and then there's your fill plug right there. REMOVE TRANSFER CASE BREATHER PLUG (a) Using a screwdriver and a hammer, remove the breather plug from the case cover. No sense in trying to drain your fluid if the fill plug is stuck, then you have no way of filling the transmission. We are the world's premier source for parts for the Mitsubishi 3000GT & Dodge Stealth, as well as many other turbo-charged imports, shipping worldwide every day. Transfer Case; Fluids & Tools Removal How to remove a stuck glow plug. I noticed that the fill plug on the transfer case was not is such good shape. Raise and support vehicle (note the warning) 2. My fill plug is frozen solid on my transfer case. This kit comes with a $75. Loosening the filler plug first is a very smart move. Here is a documented tear down and rebuild of this unit. Yes the fill plug on a 208 and 241 are hte same size - 30mm. The plug is high enough that the fluid level should be up to this point and not overflow unless it is too full. I'm looking to change the oil in the gearbox of my 1999 s3 on 90k as the gearbox is stiff when cold and it didn't used to be. But, using a website like PartsGeek. Video describing my procedure to remove a stripped Fill / Drain plug. Clean off the metal shavings (or powder) while the unit is draining, and be sure not to mix up the two different plugs. Have not checked the transfer box level yet, need a torx bit to remove the fill plug so will pick one up tomorrow. bur-wheel-drive may be engaged diængaged at any time without hing when transfer case is in. You need to check the oil in the shuttle with the engine running, but you will have to get your shuttle rebuilt before you need to worry about that oil. Our new and remanufactured transfer cases are designed to fit and operate correctly right from the start for Chevrolet, Buick, GMC, and Cadillac vehicles. Eaton transmission service manuals are provided free of charge for you to be able to diagnose and troubleshoot your transmission. On a Windows PC the easiest way to get pictures from your iPhone is to just use Windows Explorer, but there are two ways to go about this. North Carolina calls this the “One Judge, One Family” rule. Tech help on GM transfer cases. Today, I went underneath to take out the fill plug, I sprayed brake cleaner in it to give me a better look, and it was worse than I thought. Exterior Features; Bodyside/Cab Step or Running Board: Option; Bumper Step Up: Standard; Front Air Dam: Standard; Metallic Paint: Standard; Power Sliding Side Van Door: N/A; Power. I rolled over 50k miles so yesterday I changed the rear diff, transfer case (easier than engine oil), and attempted the front diff. More importantly, you want to make sure that you don't drain the fluid and then find out you can't remove the fill plug. So if you notice a leak in the component, remedy the problem to avoid chronic heart damage. Step 5: REINSTALLING TRANSFER CASE AND REAR DRIVESHAFT Put the transfer case back into the rear of the transmission. drained, remove the drain plug using a 13mm wrench and allow the fluid to drain into a clean pan. The fill plug on my Yamaha is at the water line and the boat is in the water all summer, I'm going to check out getting s seal set and the level of difficulty in replacing them -- it may be beyond my capable, but unprofessional, hands. It may not show up on the picture, but this case is actually inscribed "Drain" and "Fill". - The speedometer stays at 0 all the time. Dodge Ram 1994-2001: How to Replace Transfer Case and Seal. Set up your drain pan directly below the drain plug. Always undo filler plugs first. AutoZone Repair Guide for your Drive Train Transfer Case Transfer Case Removal & Installation. Fill to overflow with Texaco Multi-Gear 75W/90R. Drain out the old gear oil. Replace the drain plug by twisting clockwise and tightening with a box wrench or adjustable wrench. One time my mom's drain plug was stuck on her car so tight that I used a pipe wrench to get it off. You may end up getting stuck with a transfer case with no fluid. The lock for the lift gate was moved to inside the handle. 9; 90-120 psi for 7. 6L Duramax Engines, 2001 - 2016 Model Years. The amount of torque you need to put on the upper 12mm differential transfer case could pull the car down off of an improperly positioned car. The TH 400 was also used in full sized Jeeps (SJs and J series pickups) from the late 60s until 1979. First, remove the transmission oil fill plug. Tighten to the torque spec in the manual. The Case VA Series, introduced in 1942, was a new series of tractors that replaced the Case V Series (Models V, VC, VI and VO). EXTENSION CASE AND CENTER DIFFERENTIAL (1) Taper roller bearing (14) Snap ring (27) Reverse check lever COMPL (2) Transfer driven gear (15) Oil guide (28) Straight pin (3) Taper roller bearing (16) Extension case (29) Reverse check plug (4) Shim (17) Oil seal (30) Spring. While the truck was still on the stands I used my same 5gal. The filler plug as stated was removed with a 17mm wrench. In 1996 case is changed to accommodate modular motor (4. I had very little mung on the magnet from the drain plug on the transmission. I need to find the square 3/8 inch drive for the transfer case. Also remember that there are two separate fill plugs for the case and the reduction. NOT FOR USE ON DRY PAVEMENT as transfer case damage may result. You will see the Fill & Drain plug! The Fill is the 1 1/4" Plug thats not Chromed #10 Allen. Reason for Changing Oil in Transfer Case Hi Guys, is there any particular reason why you would have to change the oil in the transfer case. NP231 Edit Overview Edit. Inspect for leaks. You may end up getting stuck with a transfer case with no fluid. Convert your non locking Discovery II transfer case to a locking differential with this kit. AutoMD answers your auto repair questions by giving free help and advice from our community members. You'll notice that the drain plug is different than the fill plug. Then when you're ready to refill, you put that plug back in, and then there's your fill plug right there. I used the drain plug as it was easier to get to. Transfer-case fill plug is the large hex head on the back side (second photo). Joined Mar. Exterior Features; Bodyside/Cab Step or Running Board: Option; Bumper Step Up: Standard; Front Air Dam: Standard; Metallic Paint: Standard; Power Sliding Side Van Door: N/A; Power. The manual says to change the rear differential fluid at 28,100 miles if: a) Towing a trailer or using a car-top carrier b) Driving in dusty, sandy or wet condition c) Extended periods of idling or low speed operation d) Repeated short trips of less than 16 km (10 miles) But it doesn't say when to change it if you are NOT driving it in the above conditions. Page 909 TRANSMISSION AND TRANSFER CASE 21 - 3 DIAGNOSIS AND TESTING (Continued) A leak at the front of the transmission will be from either the front bearing retainer or retainer seal. com 3-24-2011 There is an excellent rear diff howto at. You can use Regular ATF from the Auto Part's Store or go twice the miles. I will put the long hose into the fill hole, and them pump the thing until fluid starts coming out the fill hole, indicating that the case is full to the plug hole I've had that pump forever, I believe I initially purchased it at a marine dealer, and used it to fill up lower unit gear cases on outboard motors Like so. The plug is flush with the transfer case housing. The fifth gear is designed to be an overdrive with a high-speed ratio; the ratios for the gear stages are. my big problem though is that the drain and vent plug are stuck/ corroded in place. I was better using a ten and a six inch extension. This would seem to help slow the drain flow. The differential plugs may be torqued to 36 ft. make sure the recess of the plug is good and clean, so no matter what you put in there, it will seat to the bottom, and not strip the plug. Learn how now. The shifting rail on the transfer case appears to be stuck in neutral and will not allow me to select hi or low gears Going to fill the case up with some junk oil. The install went well. But, I will put anti-seize on it wether is is new or the old one. Includes bung, fill plug and o-ring. I'm in the middle of changing fluid in my transfer case and transmission. Is this right? Is there a trick to getting a socket on it? Do I have to remove the handbrake cable first? Sorry about the noob questions. Fill ’er up Reinstall the drain plug. Disconnect transfer case linkage be prying from rubber grommet 2. 1qts of fluid if I can recall, the rear diff around 2qts and the front 1. Remember to remove the fill plug first before removing the drain plug. No socket needed - just plug a 3/8" ratchet directly into the plug. We will be towing to Michigan in a couple of weeks and let's hope this one performs as hoped and we don't get stuck with not being able to put it into neutral. 145F is untouchable. Test loosening the fill plug first using the 18mm socket; sometimes these get stuck. It has 2 bolts for drain and refill. Rear driver's view of the plunger/bracket/bolt. Stuck drain or fill plug; confusing fluid requirements; Stuck drain or fill plug. The manual says to change the rear differential fluid at 28,100 miles if: a) Towing a trailer or using a car-top carrier b) Driving in dusty, sandy or wet condition c) Extended periods of idling or low speed operation d) Repeated short trips of less than 16 km (10 miles) But it doesn't say when to change it if you are NOT driving it in the above conditions. Reinstall the transfer case crossmember. Well the fill plug bolt was stuck, last method I tried was chisel and hammer, well I was not thinking. any more or less and it will damage the transfer case because its a wet clutch system. Do you know where the transfer case fluid is located?. Torque specs: Drain plug - 27 lb-ft (24mm or 15/16") Fill plug - 27 lb-ft (24mm or 15/16") Parts: 1. Driving off-road over rough or unusual terrain requires using good driving sense. Re: Need help with Diff/Transfer Case Fill/Drain plug sizes I know the front hex for the drain plug is a 10mm. First, remove the fill plug. PayPal is the faster, safer way to send money, make an online payment, receive money or set up a merchant account. Video describing my procedure to remove a stripped Fill / Drain plug. I've been spraying it with PB blaster for several days to help loosen it but haven't found any way to get a grip on the stripped allen bolt. Clean off the metal shavings (or powder) while the unit is draining, and be sure not to mix up the two different plugs. Changing your differential fluid regularly, especially for trucks driven off-road, is a great way to keep your truck alive!. How do you check the level of the transfer case oil? I want to top up mine. To refill the case, I removed the low range fill plug first. 67-91 GM Transfer case/ drive train/ axle guide Part 1 The lower photo shows the fill/drain plugs located on the driverside of the T-221. 5qts of a mix of RedLine ShockProof and 75-90 gear oil. While changing the fluids in my truck, I stripped out the inside hex area of the transfer case fill plug. that sucker is done. The other option is to find a repair shop. If he removed his fill plug and drained that much out, then it was likely 2 qts over full. So I swapped the big magnet plug into the diff, where the larger size sticks further into the circulating fluid then stuck the low profile unit into the drain on the case. Thank you for your time. REMOVE TRANSFER CASE BREATHER PLUG (a) Using a screwdriver and a hammer, remove the breather plug from the case cover. I then drilled a hole and put in a reverse extractor, which broke off (pic below). The drain plug is easy, but the fill plug is a real PITA to get to. I was going to fill it up again, but the fillplug was stuck. Torque specs: Drain plug - 27 lb-ft (24mm or 15/16") Fill plug - 27 lb-ft (24mm or 15/16") Parts: 1. They don’t, however, have a drain plug, meaning that the only way to change the oil is to remove the differential’s rear cover. Find instant cameras and film reinvented for the digital age, plus 4K UHD TVs, mobile accessories, apparel and more. Current Part Number 2035400253 – A/T Plug Adapter (Conductor Plate Connector) – $15. The fill plug taked a 10mm hex head allen wrench. I stuck one end into the fill plug hole and with the other end of the tube up near the passenger outside rear view mirror and placed a funnel into that end and poured the oil in - gravity feed style. Rear differential was a piece of cake. Transfer Case Fill Gasket 90430-18008 27 Ft-Lb 24mm socket They apparently have a history of stripping out and getting stuck. Tips for Ford N Tractor Owners plug wells in the head with your air compressor to keep dirt and debris out of the cylinders when the plugs are removed. Astra; Audi; BMW repair manuals; Commodore; Corolla; Download Fiat Tractor Manual. Stuck drain or fill plug; confusing fluid requirements; Stuck drain or fill plug. Speedometer doesn't work and transmission doesn't shift gears. Genuine Nissan Patrol GQ GU Transfer Case Shifter Cotter Pin. Used heat (MAP/propane), pounded various size torx bits into it (T45, T47, T50 and T55; as you can see the hole is getting bigger and bigger). Question: I am converting a 21′ R. 1qts of fluid if I can recall, the rear diff around 2qts and the front 1. Still, I'm going to get that 18mm extractor and if I can get the fill plug off, I'll drain and fill again. I hadn't wanted to drive it much until I had done a transfer case fluid change. John stuck the 3/8" breaker bar into the fill plug and the square hole was totally stripped and rounded. Don't go totally apeshit. You will recieve a return shipper label to return your exsisting non CDL unit. According to Mercedes-Benz, the testing was designed to replicate worst-case conditions expected in a severe frontal crash that would cause a rupture of the air conditioner refrigerant line. It has a built-in magnet. RE: Service 4WD light IP: Logged Message: A few years ago I was doing some light 'wheelin' in my QC and as I crested a hill, I felt the transfer case/undercarriage scrape the ground. Having done that, you now will set up your pump again, fill this case with 75w90 Mobil 1, and when full, replace the fill plug. Current Part Number 2035400253 – A/T Plug Adapter (Conductor Plate Connector) – $15. Put your box end wrench on it, apply a really good amount of force and TAP the head of the plug with a hammer. No sense in trying to drain your fluid if the fill plug is stuck, then you have no way of filling the transmission. Except for military units, the production of the Case VA was interrupted in July of 1942 due to World War II. Put the spark plugs back in. The most annoying part was getting the oil into the fill plug on the rear diff. Unless you take out the spark plugs and use the kickstarter to pump the oil out. Wipe any road grime or dirt from around the plugs with a shop rag. I stuck one end into the fill plug hole and with the other end of the tube up near the passenger outside rear view mirror and placed a funnel into that end and poured the oil in - gravity feed style. These products are a perfect fit if you're looking for a Chevy Transfer Case, Jeep Transfer Case, Bronco Transfer Case, Explorer Transfer Case, Dodge Transfer Case, or Ford Transfer Case. 2L 4wd drive vehicles. Also please check out the statistics and reliability analysis of Toyota Highlander based on all problems reported for the Highlander. transfer case using a 5/8” wrench. I use a key and a piece of pipe over the end to break the plugs loose. The only thing I haven't tried is J-B welding or regular welding a bolt head to what's left of the fill plug and hope for the best. Amsoil Synthetic Automatic Transmission Fluid. That was a messy job! I’ve been told by an experienced HMMWV rebuilder that my rear-end noise is normal, so I guess my truck is fully road-worthy, except for needing its wheels balanced. 06" wide MTC-4210 SERIES TRANSFER CASE 4. notlowenuf Transfer Case Fill Plug - Stripped! eldplanko. The NV3500 is a manual 5-speed transmission and therefore is nothing like 42RE. Our oversized and rubber expanding oil drain plugs eliminate the need to replace the entire pan. Whether commuting to and from work or blasting through soft sand, your formidable Jeep Wrangler 5 speed manual transmission ensures that your wheels receive the correct amount of power so they drive at your chosen speed. Page 3 of 3 < Prev. I had a Chevy shop round out a drain plug on an oil pan and they couldn’t get it of in the wick lube (warranty oil change) after 20 min I got underneath looked at and said put a rag between the socket and bolt to take up the space tap it on et a hammer and try it. See our lemon odds and nada odds page to see vehicles with no repairs or vehicles with more than three repairs. OEM Dodge Ram 5500 Transmission & Transfer Case Parts. I need to find the square 3/8 inch drive for the transfer case. Buy roborock S6 LDS Scanning SLAM Algorithm Robot Vacuum Cleaner from Xiaomi youpin, sale ends soon. If severe, replace the oil every 30,000 miles or 36 months. Thanks Howard. is the transfer case changeover just as simple as it sounds? pull the plugs, drain, refill? the 48RE seems a bit more in depth. They won’t budge. All N-Series Tractors - Ford-Ferguson 9N, 2N, and Ford 8N. In cases where the plugs cannot be loosened, the use of an electric heat gun may make plug removal possible. Remove the drain plug, and watch the transfer case fluid pour out. Ok once you're underneath the vehicle a, you need to locate the fill plug after you've drained the fluid from the drain plug. The transfer case is used on the AWD models to transmit power from the final drive of the transmission to the drive shaft that connects to the rear axle. Log in or Sign up. I'm hoping I can remove it with some PB but it looks like I might have to remove the skid plate to get more torque on the plug. Hey All, Just completing my first major service on the vehicle solo (I know its small beans, but it was a little daunting at first). If you have both of these symptoms then the culprit is very likely to be a stripped gear inside the transfer case motor. (this is where removing it earlier comes into play, if it is stuck and stripped, you now have no fluid in the rear and no way of adding it). Your transmission also has a filter which should be changed at least every 2 trans oil changes to prolong the life of your tranny. After selecting a category you will find specific Case 300 part names and part numbers. I suspect the chain is toast and this whole thing needs redone. With 4HLc this possibility is prevented: both the front and the rear axle will get torque. Get the best deals on Other Car & Truck Transmission & Drivetrain for Chevrolet when you shop the largest online selection at eBay. Both have drain plugs as well as fill plugs. Fill plug is knurled for removal with out tools. Post Reply. Thankfully there was enough of the 3/4 square bit depression left for me to take it out. Be sure the old ring isn't stuck to the plug or the case. Remove the drain plug, and watch the transfer case fluid pour out. Motorcycle Troubleshooting Guide – Four-Stroke Motorcycle Troubleshooting Guide While this Motorcycle Troubleshooting Guide is not a complete guide of every possible cause for each problem listed, it will help assist mechanics in troubleshooting some of the most common difficulties they will face. I ordered a new one direct from ford and got it the other day. Price was $31. Most transfer cases only require a fluid change every 30,000 miles so the drain and fill plug don't move very often which can leave them. 4 wheel drive part time low - for *off road* conditions with low traction conditions and extra pulling power is needed. It's flush with the t-case housing (for reference, the drain plug is "out" about 1/16"). Yes the fill plug on a 208 and 241 are hte same size - 30mm. The drain plug is on the front of the transfer case and the fill plug is on the back side. Use only enough heat to loosen the plug. Well the fill plug bolt was stuck, last method I tried was chisel and hammer, well I was not thinking. My transfer case fill plug is in way to far. Sears did not have anything like that when I checked. I am planning to change my transfer case oil on my Challenger M2 240 jet pump. I had the same problem with my transfer case seal leaking just a little drip a the beginning of the rebuild and I was told by a Guy that works on restoring jeep not to fill the transfer case up to the top,just to fill it up about 3/8" below the plug and to use half and half 80w-90 Lucas gear oil and 80w-90 regular gear oil. Ford F-150/F-250: How to Replace Transfer Case. It would be unfortunate to drain all of your gear oil and then realize that the fill plug is stripped or frozen in place. It seems to be stuck behind the handbrake drum. brought to you by pro gear & transmission. I got a hand pump that screws on top of. The quick lube place that has been servicing my 1999 Dodge Dakota pickup for quite some time recently stripped-out the fill plug in my NV242 transfer case. How you end up with a particular judge in your family law case depends on your state's laws, but judges are typically assigned on a set rotation. This is a standard technique for removing stripped / broken pieces. As was mentioned, the fill bolt for the transmission is EXTREMELY difficult to break free the first time. I'm either blind or I need to drop the transfer case skid in order to see it, but I could not find the transfer case fill hole on my Bison. Basically, I need to get some suggestions on how to remove a stripped-out NV242 transfer case fill plug. Amsoil Synthetic Automatic Transmission Fluid. Your transmission also has a filter which should be changed at least every 2 trans oil changes to prolong the life of your tranny. Once the adjustment procedure has been completed, we request your Warranty claim for the adjustment be submitted immediately. 3 quart change around 15,000 miles also. So if you notice a leak in the component, remedy the problem to avoid chronic heart damage. The fill plug. It looks as if I'm stuck with using a pipe wrench now but I've been there. The goal here is to impact the plug with the chisel so that it will rotate in the proper direction, not to cut the plug out. You may end up getting stuck with a transfer case with no fluid. I've been spraying it with PB blaster for several days to help loosen it but haven't found any way to get a grip on the stripped allen bolt. If you can't get the fill plug out, then you don't want to proceed with draining the fluid; otherwise, you're stuck until you do get it out. Kit uses a threaded weld in bung that requires cutting a hole in the housing. This video shows how to use an "easy out" to remove a damaged fill plug from a rear differential. Genuine Honda Fluid 08200-9003 Vtm-4 Differential Fluid – 1 Gallon Bottle (Auto Accessory) 3920 Review for genuine honda fluid 08200 9003 differential. Position the motor on a work bench and you will see four retaining tabs that retain the gasket to the motor. Brian Petry wrote: I was doing my weekly check of the oil level in my transmission and transfer case and noticed that the bottom of the overdrive is level with the oil fill plug on the transfer case. Has anyone had issues where the transfer case doesn't disengage completely? I tried to check the fluid level in the transfer case but the fill plug started rounding out (%$#@) so at this point I'm probably headed to a shop anyway. Bolt is sitting almost flush with the transfer case which it shouldn't be. I love the price. Fill to overflow with Texaco Multi-Gear 75W/90R. If it is 4. Locate the transfer case fill and drain plugs on the back of the transfer case. Cause: The rear transfer case output shaft bushing is completely wiped out, this can cause the output speed sensor which is located in tail housing of transfer case instead of rear of transmission to grind into the speed reluctor wheel and causing harsh downshifts. Follow the standard sequence for placing a vehicle in motion. I ground down a 24mm socket to get clearance for the fill plug. Had to replace it due to damage I cause trying to remove it. No socket needed - just plug a 3/8" ratchet directly into the plug. And you're done! You are now feeling the smugness and self-satisfaction of someone who has done it themselves and saved a ton of cash. Dealer had to replace the transfer case servo motor with a new updated design. I have a 03 Tacoma with a bad 3RZFE, W59 tranny and J shift transfer case. Using the 10mm Allen wrench, break loose the Fill Plug. On my bike, to remove the plug I needed a 3/8" Allen head socket or Allen head tool. I think both plugs are 1/2" square. I have never taken it off. Once the adjustment procedure has been completed, we request your Warranty claim for the adjustment be submitted immediately. for parts or service call: www. Diff fluids, transfer case fluid, plugs. ('09-'13) Tranny oil + Differential oil+ plugs + Transfer case oil change? Jump to Latest Follow 1 - 13 of 13 Posts. Top the fluid up if needed. I did the front and rear diff this morning. While at it, I tried to replace the transfer case fluid and found the refill plug impossible to get at. Front Diff and Transfer Case Oil Change Howto Compliments of jspadaro @ www. This is also a perfect time to replace the spark plugs if it hasn't been done in a while. I just bought a used truck. I ordered a new one direct from ford and got it the other day. Not removed the drain plug yet. Done, now one can speculate that both the transfer and rear axle will last longer. A transfer case going dead is a like losing a part of your transmission. Replace the drain and fill plugs (internal square drive tool acess design) with the EXTERNAL HEX DESIGN plug, P/N 15032997. Drain the crankcase and fill it to the top with whatever you put in the cylinders. Remove the fill plug from the side of the. My question is, if i run the 2UZFE with a A340F, will i be able to run the J shift transfer case behind it? Thanks, Kenneth. Includes bung, fill plug and o-ring. Pretty easy. Be sure the old ring isn't stuck to the plug or the case. 1994 FORD TRUCKS EXPLORER 4. , and the transfer case plugs to 25 ft. Hi everyone, I can't remove the drain plug to the transfer case. The case is an NV244 which is full time awd but it as has a selectable hi/lo range like a traditional 4x4. 2nd Gen transfer case fill plug. Changing your differential fluid regularly, especially for trucks driven off-road, is a great way to keep your truck alive!. Visit my website to get 20% off of your first service with a code at www. Toyota Tundra 2000-Present: How to Change Front and Rear Differential Fluid. Remove the motor from the transfer case and set aside. To see how frequently Mazda CX-5 problems occur, check out our car reliability stats. It would be unfortunate to drain all of your gear oil and then realize that the fill plug is stripped or frozen in place. Draining the Transfer Case. Then undo the extension case drain plug (C) to remove any last traces. I refilled with 1 quart 8 ounces, to. For the transfer case, after draining it, put the plug on, and just take the fluid bottle, shove it in the fill hole, and squeeze like crazy. Have not checked the transfer box level yet, need a torx bit to remove the fill plug so will pick one up tomorrow. tacomaworld. Both the drain and fill plugs on the rear diff simply accept the drive of a 3/8" square drive. OK, so I was changing the oil in my transfer case (97 fwd) and I removed the drain plug. Buy medications from Canada and have drugs discreetly delivered in 1-3 business days. You could also check to see it the t-case is acting up by shifting it in and out of 4x4 next time it acts up. This video shows how to use an "easy out" to remove a damaged fill plug from a rear differential. My own Gear Box refill kit. transfer case using a 5/8” wrench. You can tell when it's full by opening the little petcock on the side of the main case. Most transfer cases have a fill plug and a drain plug. As I mentioned before, I have seen the NP231 Transfer Case come with 2 different types of fill and drain plugs. If you look at a standard DSM transfer case, you will again see an unmachined hole/plug where the plunger is on the switchable case. 1/2 MPT Ford Aluminum Plug With Sealer. Performed on a GMC Sierra. 06 qt (definitely verify this) 4. open the fill plug near the top of the differential rear cover plate. While the truck was still on the stands I used my same 5gal. To keep your rear differential oil in place, you need a quality plug that won't buckle under off-road pressure.