stuck cross threaded nut/bolt!!!!

[97spyder maayng]

OK, so I was changing the oil in my transfer case (97 fwd) and I removed the drain plug. I was going to fill it up again, but the fillplug was stuck. I tried everything to take that 17mm off (closed wrench/hammer, vice grips/hammer) and sadly it ate up the nut and rounded it. That was when i decided I needed to use the plummer's wrench (because it's round now, and plummer wrenches dont slip).

It ends up that whoever changed the transaxle fluid, stupidly put the fill plug back on by an air gun, and CROSS THREADED IT, ruining my threads and wedging the plug slanted sideways in, impossible to remove by hand.

I haven't tried heating it up yet (expanding the aluminum transfer case), but does anyone know a good method in removing it? Would i need to get the inside transfer case threads re-threaded? OR can I fill the transfer case another way? if so details plz.

THANX!

 

[Lordpaxin]

you can either, Pull the xcase off, fill to the proper amount through the drain plug by holding it upside down, seal it off, remember the output shaft doesnt seal unless the shaft is inserted.

slide the xcase back onto the shaft, flip it right side up, and bolt it back on.
you may have issues with the vent on top, might leak alittle, but im sure you can be quick about it.


another way.

get a dremel tool, with a grinding or cutting wheel, and another socket, the next size down, or US standard size smaller to be closer, slowly grind away at the bolt and keep trying the socket, when it almost goes on, get a hammer and tap it onto the bolt, this will ensure a good fit. 6point is better.

use a long breaker bar and hold on.
of course this method may render your socket unusable.

good luck.

 

[Defiant]

You've found out why it's crucial to remove the fill plug first.

Pull the speed sensor drive, measure the proper capacity, and fill it through there with a funnel.

Don't drop the tiny screw into the gearbox (in case you needed to be told that, too). And don't go wild while tightening it down.

 

[92GSXman]

Are you talking about the transmission? You mentioned that it was FWD.

 

[Lordpaxin]

I thught it was a xcase.

 

[Defiant]

Oops, nevermind.

 

[Lordpaxin]

My My my moderators these days............

 

[97spyder maayng]

sorry bout that, i havent gone on here in a few days...i ment to say transaxle, not transfer case.

but anyways, has this happened to anyone?

 

[Defiant]

...i ment to say transaxle, not transfer case.

It's like a psychic hotlink. I'm amazing.

 

[marcmsj]

It's like a psychic hotlink. I'm amazing.

now we know where miss cleo went... she's hiding on dsmtuners

 

[Defiant]

now we know where miss cleo went... she's hiding on dsmtuners

Unless she's tied up in a spare room somewhere, for "research".