300Tdi Transfer box Drain Plug Stripped

Will11 · Aug 18, 2019

Been doing a full service on the 300tdi 90 today and got to the transfer box (R380) drain plug and managed to strip the threads and the plug just spins in the hole but doesn’t leak. I’ve tried a screwdriver behind the head whilst trying to unscrew it.

Im a bit stuck really as the plug is into the main body of the transfer case.

marjon · Aug 18, 2019

Oppps.

Are we talking gearbox or transferbox?
Your ref R380 is the gearbox.

If it is the transfer box then isn’t the plug right next to the sump plate? ( haven’t been under ours for ages) you may have to remove the sump so you can apply some pressure from in side to help get it out, then for me it’s helicoil country.

Good luck

Will11 · Aug 19, 2019

Yea its the transfer box, had a go trying to remove the sump tonight, but I think its goong to be a weekend job.

payydg · Aug 19, 2019

That’s going to be a pain. I’m not sure taking the dump off is going to help As I think the intermediate gear +/- input gear will be in the way. Have you got a slide hammer?

Will11 · Aug 19, 2019

Just found out the hard way, gear is in the way (see photos) I think a slide hammer will be getting ordered at some point tomorrow.

I take it I’d have to weld the slide hammer to the nut and then try and force it out?

payydg · Aug 19, 2019

Will11 said:
Just found out the hard way, gear is in the way (see photos) I think a slide hammer will be getting ordered at some point tomorrow.

I take it I’d have to weld the slide hammer to the nut and then try and force it out?

Probably not, you can get very comprehensive ones that have a hooked attachment and a gripper that should work. I've got this set. Don't often have to use it but when I do I'm very glad I've got it

https://www.otctools.com/products/9-way-slide-hammer-puller-set

marjon · Aug 19, 2019

I would be very careful about pulling and hammering on it, you may end with a chuck of cast ally in you lap

If you can’t get in there with some sort of bent lever and apply pressure, then I would hold it and drill it out personally.
Either drill for a bigger plug or helicoil, you need the sump off to clean out bits anyway.
It’s not an easy one good luck.

J

dag019 · Aug 21, 2019

marjon said:
I would be very careful about pulling and hammering on it, you may end with a chuck of cast ally in you lap

If you can’t get in there with some sort of bent lever and apply pressure, then I would hold it and drill it out personally.
Either drill for a bigger plug or helicoil, you need the sump off to clean out bits anyway.
It’s not an easy one good luck.

J

If you are going to be drilling it out, for the amount of extra effort I would remove the box and do it on the bench rather than try and do it cramped under the land rover. You should then be able to do it fairly carefully and precisely. I should only take you about an hour half to drop the tbox off as long as everything comes off easily. I have just done mine again to send the gearbox off for warrantee work after its rebuild!

payydg · Aug 21, 2019

dag019 said:
If you are going to be drilling it out, for the amount of extra effort I would remove the box and do it on the bench rather than try and do it cramped under the land rover. You should then be able to do it fairly carefully and precisely. I should only take you about an hour half to drop the tbox off as long as everything comes off easily. I have just done mine again to send the gearbox off for warrantee work after its rebuild!

Was that an Ashcroft box?

dag019 · Aug 22, 2019

payydg said:
Was that an Ashcroft box?

It was indeed. I lost 5th gear, but I am not sure it was entirely their fault! I am guessing it was a manufacturing issue (see below pic). The returns process was nice and easy and they turned it around and got it back to me inside a week so was good service overall. broke on the firday, weekend to remove it, collected Tuesday, returned to me on the Friday and refitted the weekend, so it was only off the road for a week.

payydg · Aug 22, 2019

dag019 said:
It was indeed. I lost 5th gear, but I am not sure it was entirely their fault! I am guessing it was a manufacturing issue (see below pic). The returns process was nice and easy and they turned it around and got it back to me inside a week so was good service overall. broke on the firday, weekend to remove it, collected Tuesday, returned to me on the Friday and refitted the weekend, so it was only off the road for a week.

View attachment 187638

That is some failure. Just fitted my ashcroft box but has been fine really - other than the gear selector needs a little bit of adjustment but will get to that at some point.

300Tdi Transfer box Drain Plug Stripped

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