Is my front case junk?

[NOSLO2PT0]

I had a hell of a time getting the castle plug off, and in the process, beat the front case up pretty good. The area where the o-ring sits has some pretty nasty gouges in it. Can I reuse this without fear of it leaking or do I need to buy another one?

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[Dericsh]

I hope someone proves me wrong but I don’t think I’d be reusing that.

 

[steve]

Mike, do you have access to a TIG and Mill? If the rest of the case is in good shape that could be cleaned up to seal again but if you have to pay someone to fix it you might be better off getting another one.

 

[NOSLO2PT0]

Steve, that I do not. I really didn’t want to spend $150 on an ACL front case, but it’s looking like I may have to

 

[luv2rallye]

Correct me if I'm wrong but as I remember the o-ring goes around the plug's threads and is pressed against the inner flat recessed area - not in the gouged up area. So you should be ok with a little cleanup of the gouges.

I removed mine with the engine still in the car and so to avoid gouging it I got this tool: https://mitsubishi.service-solutions.com/Detail/15/MD998162-01-PLUG-WRENCH which worked perfectly.

Jafro in his "6&7-Bolt 4g63 Front Case & Oil Pump Rebuild" video says everyone destroys this plug and to not touch it. Of course he had the engine out of the car where he could do things another way.

 

[steve]

I made one of those tools from copper pipe, I wish I would have had the right tool. Thankfully I didn't shear the castellated teeth off the first time I used mine and the plug came out.

 

[NOSLO2PT0]

I made the tool as well. My tool making skills were lacking and it didn’t work very well. That’s when I resorted to the torch and bigger hammer and screwdriver routine. Once I got the plug off, I was able to tweak the tool so it works