How to fix stripped transfer case threads?

My fill bolt on my transfer case is stripped. I figured it out when I changed the transfer case fluid when I first bought the truck. Anyone have a solution? What about ptfe (plumbing) tape? AutoZone didn't have a helicoil large enough for it. And what's it's diameter? Thanks peeps!!

 

Your best bet is to drill it out and re-tap it with a slightly larger diameter thread tapper. Personally I'd try to stick with metric so that you can carry around one set of tools, but that's totally up to you.

Tap and die sets are expensive and that's a big tap so you're not likely to use it much in the future, so it might be reasonable to go to a shop to have them do it for you... Plus, when you drill it out and re-tap it, you'll be creating metal shards...and you for sure want to get those out of the case .

Good luck!

 

Is it backing out or leaking?

If just for concern, the PTFE tape should help hold it from backing out or seepage.

I'd be afraid of just opening a can of worms trying to re-tap it and getting all the shavings out.

 

It is funny how life works... I just happened to click on @Speedytech7's build thread a few minutes ago, and I noticed that one of the first things he did was re-tap this puppy. Post #6! You know Zane, I think your knowledge level has increased in the last four years... I mean, just from your writing

 

no doubt if it has no bite at all it has to be fixed.

I would also think heli-coil makes a repair kit that large, just not available at parts stores if you want to be able to use stock plug and crush washer in the future.

Guess I was more worried about all the shavings and whether I trusted getting them all out w/o splitting the cases and doing this on a bench vs. just replacing the case with another.

 

I sure hope so, I didn't know shit then haha. At that point I had no desire to even lift my truck, only reason I did is because my stock leafs shattered. I was a bit lazier with TW then too, and my writing certainly shows that, I never thought anyone would read what I wrote honestly.

As far as tapping this over goes, it won't be a huge deal, get the proper size tap that's up a size, coat it in thick grease to hold the shavings and tap it out. Drain and fill the case once or twice and she'll be good to go. Don't have to worry so much about the shavings, they're soft aluminum and very small.

 

Taps and Dies can be bought as you need them no reason for a complete set of sizes you never use

 

I was hoping the ptfe tape would work. I know its not the end all solution, however, I dont think its stripped that bad. Just wont tighten down. Giving me a consistent leak whenever im not level.

 

Try to clean the threads with a tap and use a new drain plug

 

If I remember correctly (its been a while since I got in there) the threads in the housing are stripped. I'm gonna check it out again today. Hopes is that the ptfe fills the gaps and lets the threads eat. Also, creating a seal underneath the head of the bolt. We'll see I guess...

 

if going the oversize and new threads coat the drill with wheel bearing grease and drill slow and the shavingw will stick to the drill bit, same goes for the tap.