Transfer case drain plug.....

[Bonehead]

Trying to change the oil in the transfer box tonight, obeyed the Haynes, 30nm max. torque wrench setting, just spun away on me.

Plug won't tighten, won't come out. Tried a little bit of oil in box to see if it's tight enough, but a drop seeped past the plug...Damn!

Have I stripped the plug threads or the case threads? And if it is the case, is it easy to tap a wider hole?

Must admit, don't fancy buying a transfer box because of a drain plug.

Thanks in advance,

[Bonehead]

Oh yes, and any idea how to get the f***ed one out?

Cheers again,

Mark
'94 300 TDi Manual

[Paul Grant]

You've stripped the threads on the transfer case. It's aluminum an it can happen easily enough. You'll need to install a Heli-coil to properly rethread it. To remove the plug try to apply as much downward pressure on the plug as you can while turning it. A vise grip might help.

[Bonehead]

That's what I thought. Trying your suggested exctraction method.

Cheers,

Mark.

[Bonehead]

Oh yes, anyone know what size I need?

Thanks.