Question about transfer case

Hello, I started to drain the fluid in my transfer case, all went well but when I went to take off the refill bolt i noticed that it had been rounded off and there was absolutely no way I could get it off. I wish i had picture to show how bad it is rounded. I didn't notice because it was covered in mud and if I had I would have never drained it.

Is there any way to refill my transfer case other than having to remove the refill bolt?

I called a couple place and they wanted 150+ just to take the bolt off and they didn't guarantee that they would be able to. I also would have to pay to get it towed there since the case is bone dry. Any ideas would be greatly appreciated. Thank you for your time.

 

There are all kinds of tools to get a rounded bolt off. Even vise grips has a wrench designed for that. You could even try filing 2 sides flat. How do you think a service shop does it? Get it out then buy a new bolt.

 

There should be a breather tube for the T-case. Remove the breather tube and pump fluid in at the fitting. Use a hand pump and inject the quantity stated in the owner's manual. Note access may be tight.

 

Just ran into this the other day - but I rounded the fill plug hole prior to removing the drain....

Ultimately, I had a friend weld a nut to the fill plug and it did the trick. I did replace the fill plug/washer with one from a dealer.

I tried without success:

PB Blaster and Liquid Wrench
Vice Grips and pipe wrench
Hammer and Chisel
Heat

and different combinations of those tactics.

You can add fluid through the top of the transfer case. Remove the center console and pull the shifter lever assy. I've also heard of someone filling through the transfer case breather.

But 5 minutes at the welder and it was done. He wouldn't take any money - so left him a 20 on his welder to discover after I had left...

 

Yeah it was my mistake to not check the filler plug hole first. Thank you so much for the quick replies and I will try to fill through the transfer case breather

 

Take your center console out, pop off the shifter boot, remove the shifter and pour in. It sounds like a lot of work but its easy. Far easier than going through the vent tube.

 

Exactly. I choose this method anyway because it's easier and less messy than trying to get oil into that fill hole, even with my pump.

Just make sure you use the proper amount of oil that is called for in your manual.

 

Thanks again!