Transfer Case Fill Plug Needed

[Artago]

Hi all,

Back Story
I was driving along minding my own business when I hear what sounds like a rock bounce through my under carriage. I didn't think much of it and drove home. The next day I drive out and I can smell some burning metal, almost like clutch. I get home and check out the under the car. So my transfer case fill bolt is missing. WTF

I need
So I need a new bolt. Where can I get one besides the stealership. Oil pan bolt should work correct?

https://www.extremepsi.com/store/product.php?productid=22304&cat=864&page=1

Thanks,

Tom

 

[LiquidX]

I would get the xfer case looked at too for any gear damage which you most likely have. It's only 5 bolts to drop it.

 

[JusMX141]

Not sure what the thread pitch is on the t-case fill plug, but you should be able to get one at any local (competent) auto parts store.

 

[talondave]

Oil pan plug wont work, i have tons of those fill plugs just not sure what it takes to mail one to Canada.

 

[bryanwheat]

It is the same as the transmission fill plug (assuming you have a 5 speed). Pop it out and take it into the parts store to compare. I also wouldn't be surprised if there is damage inside the transfer case. You likely splashed most of the oil out.

 

[Roberti 2G]

Try STM: 90-99 DSM PERFORMANCE PARTS

 

[eclipse012]

call around to some of you local quick lube change shops. I know some of them keep extra drain plugs and fill plugs incase they round off the head of the plug or they are too rusted out. You never know, you may luck out and find a new one cheap

 

[Artago]

Ok so I have a 1G on blocks, so I just "borrowed" the t-case bolt off that.

I would get the xfer case looked at too for any gear damage which you most likely have. It's only 5 bolts to drop it.

I only drove it for about 15 miles (2 trips). I will tear it down when I pull my tranny out. T-case and tranny are both getting rebuild. I'll be sending them off to Jack when I get my 1G back up and running.

Not sure what the thread pitch is on the t-case fill plug, but you should be able to get one at any local (competent) auto parts store.

Awesome, I'll try that.

Oil pan plug wont work, i have tons of those fill plugs just not sure what it takes to mail one to Canada.

USPS priority. Just stuff it into a padded envelope. Should be $8-$15 ish to ship it. If you are willing to do that for me let me know.

It is the same as the transmission fill plug (assuming you have a 5 speed). Pop it out and take it into the parts store to compare. I also wouldn't be surprised if there is damage inside the transfer case. You likely splashed most of the oil out.

Most of it came out but it wasn't completely dry when I had a look. There was still some oil in there. I filled it back up and used the bolt from my 1G. Drove it around last night and to work today to test it. Seems to be fine for now but I will definitely have to rebuild it.

Try STM: 90-99 DSM PERFORMANCE PARTS

If I can't find one locally then I'll check them out.
-----------------------------

Thanks all,

Tom

 

[JusMX141]

It is the same as the transmission fill plug (assuming you have a 5 speed).

If this is true, then it's a 16mm x 1.5 plug....Dorman part #090-054. Sells for $2.49 w/gasket at my workplace.

 

[talondave]

If this is true, then it's a 16mm x 1.5 plug....Dorman part #090-054. Sells for $2.49 w/gasket at my workplace.

Yeah its the same, that and crush washer are the same!

 

[Artago]

If this is true, then it's a 16mm x 1.5 plug....Dorman part #090-054. Sells for $2.49 w/gasket at my workplace.

I thought it was 17mm? At least that's the wrench I've been using

 

[agentorange313]

I thought it was 17mm? At least that's the wrench I've been using

16mm x 1.5 is the thread pitch not the wrench size. The bolt head is 17mm

 

[bryanwheat]

I thought it was 17mm? At least that's the wrench I've been using

You are talking about the head of the bolt, they are talking about the threaded part of the bolt.

 

[Artago]

16mm x 1.5 is the thread pitch not the wrench size. The bolt head is 17mm

Awesome, thanks for the clarification.

So if I went down to a hardware store I need a M16 x 1.5 x 25mm bolt?

 

[bryanwheat]

Awesome, thanks for the clarification.

So if I went down to a hardware store I need a M16 x 1.5 x 25mm bolt?

you probably won't find a flange head bolt at the hardware strore. Go to the parts store and get one from the oil drain plug section.

 

[JusMX141]

25mm seems awful long- although I haven't had a t-case fill plug out for a while. I think you would want it to be more like 15mm in length, and try to find something with a flanged collar at the top to seal against the housing:

You must be logged in to view this image or video.

 

[agentorange313]

Awesome, thanks for the clarification.

So if I went down to a hardware store I need a M16 x 1.5 x 25mm bolt?

Yes, if the length of the bolt is 25mm from the factory.

Not sure of the length, it hasn't been mentioned above, but according to Dorman part number its: "under - head length" is 13mm
Dorman/Oil Drain Plug (090-054) | AutoZone.com

 

[Artago]

Just of off the phone with the dealership. They told me it's 16mm x 16mm. They were unable to tell me the thread pitch but 1.5mm sounds right.

I'll buy one from the hardware store and try it out.

 

[bryanwheat]

25 is way too long. Make sure that you get a copper crush washer to go along with it also. Most of those plugs come with a rubber or plastic gasket which is not a good idea for this.

Just of off the phone with the dealership. They told me it's 16mm x 16mm. They were unable to tell me the thread pitch but 1.5mm sounds right.

I'll buy one from the hardware store and try it out.

As i said earlier, you likely won't find a bolt with the flanged head at the hardware store. It has to have a flange or else there is nothing to seal up the crush washer. Just go to the auto parts store.

 

[JusMX141]

Again, in case you missed it- I gave you the freakin' Dorman part number above...just pick up the phone and start calling parts stores in your area asking if they have that part number or something equivalent in size. By the time you screw around with the incorrect bolt from a hardware store and chance it leaking...it's just not worth it.

 

[Artago]

Again, in case you missed it- I gave you the freakin' Dorman part number above...just pick up the phone and start calling parts stores in your area asking if they have that part number or something equivalent in size. By the time you screw around with the incorrect bolt from a hardware store and chance it leaking...it's just not worth it.

Thanks Justin, I'll definitely do that!

I appreciate your help it's just that I'm at work right now so I didn't reply appropriately.

But thanks again!

Tom