Threaded!

Tried to change the transfer box oil but have now over tightened the drain plug (didn't think 30Nm was that low!). The plug won't now come out and it just keeps turning either way. Have tried wedging it with a screw driver and using mole grips to get the plug out. So....
1. Any helpful suggestions on getting the plug out without damaging anything else
2. Which thread will be damaged?
3. Have a new plug and washer on order but what should I do if it's the transfer box thread damaged?

I'm leaning lots!

The Godfrog said:

Tried to change the transfer box oil but have now over tightened the drain plug (didn't think 30Nm was that low!). The plug won't now come out and it just keeps turning either way. Have tried wedging it with a screw driver and using mole grips to get the plug out. So....
1. Any helpful suggestions on getting the plug out without damaging anything else
2. Which thread will be damaged?
3. Have a new plug and washer on order but what should I do if it's the transfer box thread damaged?

I'm leaning lots!

Click to expand...

Guessing it is likely that the alloy thread in the box will have gone, rather than the thread on the steel plug. Not sure, I have never done that myself.
Try locking moles onto the plug, and pulling hard and turning anti-clockwise at the same time.
Ideally, if the thread in the box has stripped, get a helicoil insert, PTFE might hold it for a while if carefully applied.

Thanks Turboman - I tried the "locking moles onto the plug, and pulling hard and turning anti-clockwise at the same time" but to no avail. I'll try again.
Off to look for a helicoil insert now..

now I'll need to know to use a helicoil kit..... damn and blast my ham fists!

Helicoils are quite straightforward to do, read the instructions and take it step by step, drill, tap, fit coil, make sure that the coil is properly seated in the thread, remove the tang. I've done thousands using Recoil kits which I've found very good.
HTH
Mo

Thank Mo. One thing that would concern me after seeing how its done on line is the "tang" that you need to break off at the end. Doesn't seem a good idea to push it into the transfer box.

Remove the bottom cover and put a couple of fingers full of grease on the inside on top of the drain hole to catch it ?
Mo

Mo Murphy said:

Remove the bottom cover and put a couple of fingers full of grease on the inside on top of the drain hole to catch it ?

Click to expand...

If I remove the bottom cover can I get my fingers (or something less chubby) in there to help get the drain plug out? Will I need a new gasket as well?

The Godfrog said:

If I remove the bottom cover can I get my fingers (or something less chubby) in there to help get the drain plug out? Will I need a new gasket as well?

Click to expand...

Always use a new gasket when you remove one.

Of course - wasn't thinking!
Anyone know what size and type of thread the drain plug is so I get the right helicoil?

Godfrog, to get the plug out you need to exert outward pressure under the head whilst rotating the plug. Try and get something under both sides of the plug head, a couple of screwdrivers or a couple of small cold chisels gently tapped in. You may have to exert more force than you probably think is appropriate
Good luck with it
Mo

If your thinking of taking the plate off anyway you could try drilling a hole through the plug and using a drill/driver try screwing a large self tapper through said hole from the inside. You will be pushing hard and the screw will be trying to rotate the plug the right way down the thread.
Might even find when drilling the plug (at low speed) the drill bit will catch and do the job anyway.
Good luck.

The Godfrog said:

Tried to change the transfer box oil but have now over tightened the drain plug (didn't think 30Nm was that low!). The plug won't now come out and it just keeps turning either way. Have tried wedging it with a screw driver and using mole grips to get the plug out. So....
1. Any helpful suggestions on getting the plug out without damaging anything else
2. Which thread will be damaged?
3. Have a new plug and washer on order but what should I do if it's the transfer box thread damaged?

I'm leaning lots!

Click to expand...

I have just had exactly the same problem and was equally surprised at the small amount of force needed to cause trouble. In my case the plug sheared off at the shoulder just above the head. Having tried to get the remains out by various means I called in help from a neighbour who works for an independent LR garage. He spotted that the plug had actually sheared at the bottom of the magnet leaving a small amount of hollow thread with the magnet inside it. Attempts to gently tap the plug around just rotated the magnet in the 'sleeve'. At first we thought that the threads had completely stripped as the plug appeared to move up into the box, but we realised that it was the magnet sliding up out of its threaded sleeve.

Eventually we decided that bravery was needed! Having removed the bottom cover plate, which doesn't give direct access to the top of the plug because there are gears in the way, he pushed the magnet up completely into the box. A little jiggling with some stiff wire and rotation of the gears (by hand with the transfer box and main gearbox in neutral) the magnet was recovered (it tended to sit neatly in the gear teeth). He then found that the remaining, hollow part of the plug could be removed with a large screwdriver blade using almost no force. Luckily, the only damage to the thread in the transfer box was to the very first turn. The new plug went in and torqued up fine. All that was then needed was to replace the bottom cover, having cleaned it up and applied a bead of RTV sealant. Finally, of course, there was the profuse thanks stage!

Good luck with getting the damaged plug out.