Transfer Case Fill Plug Stuck

In this step I'm going to demonstrate the proper service procedure for locating your fill plug, filling your transfer case and reinstalling your fill plug. It's flush with the t-case housing (for reference, the drain plug is "out" about 1/16"). Learn how to replace the transfer case output shaft seal on a 1989 Jeep Wrangler How to Move a Ford Expedition That Is Stuck in Park How to Fill Washer Fluid. dont know whats going on. Any advice or pics of the fill plug would be greatly appreciated. Is this right? Is there a trick to getting a socket on it? Do I have to remove the handbrake cable first? Sorry about the noob questions. I did the front and rear diff this morning. Brian Petry wrote: I was doing my weekly check of the oil level in my transmission and transfer case and noticed that the bottom of the overdrive is level with the oil fill plug on the transfer case. GM has issued a TSB #99-04-21-001 to discuss methods to remove stuck transfer case drain plug. Transfer box filler plug stuck If I can't get it off can I just empty what's in there and re-fill from the top, just putting in the correct amount (2. Any foul/burnt smell gritty texture indicates the oil is spent and an oil change is needed. Took some effort, was not easy. Mine came off pretty easily. I thought I would drain the fluid first and when I went to remove the plug, I noticed that somebody else had stripped it out a little. All gear ranges including reverse are synchronized. Transfer case fill plug (circled in red). Then, replace the plug. This could be indications of overheating conditions previously. Fill up through the fill hole until you have fluid leaking out. Two versions of the NV4500 are used in 1994+ models. Allow fluid to drain 5. Further testament to VW's design goals is the inclusion of full time all wheel drive, a low-range transfer case, ABS and Traction Control that include an off-road mode of operation, available locking center and rear differentials, and an optional air susp ension with adjustable ride height. Step 2: Locate the drain plug, which is a hex-headed plug located on the bottom of the trans, somewhat farther back than the fill plug. Mark front and rear propeller shaft yokes for alignment reference. Also please check out the statistics and reliability analysis of Toyota Highlander based on all problems reported for the Highlander. From fuel filters to plow shares, the odds are that Messicks has the parts you need. for those who know the name, no i havent done any work on my runner mainly czu of no money and its been too freakin cold out either way i havetn been drivin it czu of bad tags any way, the fluid in my t-case came to mind after lookin thru my haynes manual, so i went to try and get the fill plug out to check the fluid, and its stuck, and i have bad luck with stripping bolts, so i stopped. Place a drop cloth and drain pan in the area under the transfer case before you remove the drain plug—this can be a messy job. If the main output shaft fractures, the vehicle may lose motive power, increasing the risk of a crash. Use the drain in the bottom of the axle housing and the fill plug on the pan to refill, and unless it's leaking, leave the pan alone. Have your bucket handy Once the transfer case has drained, replace the drain plug and torque to 39Nm. So I swapped the big magnet plug into the diff, where the larger size sticks further into the circulating fluid then stuck the low profile unit into the drain on the case. Then when you're ready to refill, you put that plug back in, and then there's your fill plug right there. Anyway it broke, well JB weld be good enough to fix this. Forum discussion: 2004 Liberty 180K I went to change the fluid for my transfer case (2 plugs with 10mm allen) and Valvoline fucked me by partially rounding the hole in the drain plug the last time. Getting to vent plug in top seems difficult. It looked pretty dirty, Want to replace the fluid in transfer/axle case but can not locate fill plug or drain. Transfer case drain and differential plugs look just like the pictures. Also worth noting is that neither the drain nor fill plug had any significant metal particles on them. All of my oil looked great accept the front transfer case oil which had metal filings stuck to the magnetic drain plug I had in place (pics attached). Rear diff went fine, then onto the transfer case. Try to move the shift pawl on the transfer case with a 9/16" wrench. The SR4 transmission case is 9-1/4" long in addition to its 6" shifter / tailhousing assembly; for a 15-1/4" total length. For the transfer case i went with STP ATF-4 (I have the BW 44-45), bought 2 bottles, used around 1. Can anyone help me find a t case fill plug / washer for a limited 1996 3. Position the drain pan under the transfer case. 7 is Stuck in 4 wheel drive unable to shift back to. Find out how you can avert disaster with this mandatory fix for 2001-2007 Gm transfer case fix. If you can't move the shifter bracket out of the way you will have to drop the front drive shaft out of the way. The transfer case is crucial for maximizing traction and ensuring smooth operation of the drivetrain. I used the drain plug as it was easier to get to. to completely fill the transfer case after I drained it. Pour the fluid in the fill hole until it runs out of the check plug hole, replace the plug, close the fill hole by putting the dipstick back in and reinstall the handlebars if you removed them. I'm either blind or I need to drop the transfer case skid in order to see it, but I could not find the transfer case fill hole on my Bison. To keep your rear differential oil in place, you need a quality plug that won't buckle under off-road pressure. Had to replace it due to damage I cause trying to remove it. Both of the fill holes are all vertically oriented, so you need. Drive around to get the transfer case warmed up. This can be done without a press, and with basic tools. It's just a 1/2" ratchet or 3/8" ratchet. The manual calls for fresh lube in the axles and the transfer case, too. Remove it with a 24mm. The drain plug is located on or near the bottom of the differential while the filler/service plug will be on the side and closer to the top. Drain and Fill Transmission Fluid; Toyota Automatic Transmission Fluid Dextron II/III (3 Quarts) At. Remove the drain plug and allow the t/case to drain. Bolt the case into place and secure it. I tried to hammer a little bigger torx bit in, but could not get it to budge. 100" thick o-ring on the drain & fill plugs. I took a lid with a nipple off a bottle of gear oil and then put a small piece of 3/8 hose on the end of that to put in the whole to keep it clean. After draining and re-installing the plug, refill the unit until oil starts to spill out the fill hole. Here are some pics of what I did. After 4 drain and fills I imagine the tranny can go on a 15k drain and fill schedule. Working on a 2000 Dodge Durango with a nv242 aluminum transfer case. The centerline of the. Pretty easy. Transfer Case (NV241OR). REMOVE TRANSFER CASE BREATHER PLUG (a) Using a screwdriver and a hammer, remove the breather plug from the case cover. Place the transfer case back onto the floor jack and roll it under the vehicle. After 4 drain and fills I imagine the tranny can go on a 15k drain and fill schedule. Remove the fill plug first. It will help you troubleshot and diagnose your Eaton transmission. The tool needed depends on the transfer case, but it may be a 10mm Allen bit. The NP205 gear driven transfer case is considered by many to be the king of bulletproof. I stuck with the recommended mopar fluids in all three. (if it is seized and you drain fluid, there will be no way to re-fill and you will be stuck) 2. Locate the transfer case fill and drain plugs on the back of the transfer case. The transfer case is the heart of your 4WD Dodge Ram. Remember to remove the fill plug first before removing the drain plug. When the fluid warms up it will expand and should run out of fill plug, if it does not, add fluid until it starts to run out. Looking for transfer case fill plug on 1995 chevy blazer front. Reinstall the fill and drain plugs in the tranny (hand tight) and then slide the drain pan under the transfer case drain. com, we take pride in our huge inventory of parts for many Jeep models, such as our vast selection of Jeep transfer cases for sale and transfer case yokes for sale, as well as sprockets, gaskets, flanges, balls and every other piece you need to put together a great transmission mechanism. Have new fill and drain plugs along with new crush washers. Now my issues. AWD Front Diff/Axle/Transfer Case. NV4500 Manual Transmission Exploded View. I need to find the square 3/8 inch drive for the transfer case. Jump to Diagnosis. it will expand the diameter of the hole, heating the plug expands the plug in the hole. Check for leaks, pray your computer doesnt go haywire like ours has and still is only shifting into first and second. In my 1997 Explorer XLT (4 x 4), I had a problem with the transfer case, it was engaged all the time and too expensive to replace, I never used it, he took the small axle out, the one that goes. RANGE C1 CL. Kubota: RELAY, GLOW PLUG, Part # 16415-65600 Buy Online & Save. Any easy way of removal? I thought about drilling it and using an easy out, but I'm afraid of getting shavings in the case. Apply pipe sealant, P/N 12346004 (Canadian P/N 10953480), or equivalent, to the fill plug threads. The NV4500 is a 5-speed constant mesh manual transmission. Hello, My dart is at 65K miles, and I know it's time to change the transmission fluid. Clean area around fluid drain plug, remove plug and discard the sealing washer. The transfer case is not the transmission, but the part that allows the vehicle to shift from 2WD to AWD. Remove the square fill plug on the knuckle and take a sample of the grease. Work the ratchet and 24 mm socket between the transmission and the exhaust pipe (tight squeeze) and then Break loose the fill bolt, then slide the oil drain pan under the tranny and remove the DRAIN bolt. 5 X 20 Bottom pan drain plug - Transfer case to. Performed on a GMC Sierra. I rolled over 50k miles so yesterday I changed the rear diff, transfer case (easier than engine oil), and attempted the front diff. case so i can't drive it anywhere. Transfer box filler plug stuck If I can't get it off can I just empty what's in there and re-fill from the top, just putting in the correct amount (2. RELAY, GLOW PLUG. What I mean by stripped-out is not the threads of the plug or the case, but the hex socket itself in the fill plug. The growl howl could be front drive line spinning with no tension. Its now stripped and was hoping to buy a replacement. An exhaust rubbing the t-case or transmission will ring like crazy at certain speeds/rpms. The front output shaft oil seal is located on the front of the transfer case on a four wheel drive vehicle. The fill/service plug is usually not a traditional looking bolt, but rather has an opening for a 3/8 inch drive ratchet. Indy Mechanic pulled a computer code showing the transfer case fluid was problematic. Convert your non locking Discovery II transfer case to a locking differential with this kit. For the transfer case i went with STP ATF-4 (I have the BW 44-45), bought 2 bottles, used around 1. Clean area around fluid drain plug, remove plug and discard the sealing washer. Whether you're looking to maintain, optimize, or upgrade, we offer competitive pricing on Crown Automotive Differential Fill Plug - J4004751 for your Truck or Jeep at 4 Wheel Parts. Transfer case drain and differential plugs look just like the pictures. NP205 Rebuild Guide. If I remember correctly, the vent for the transfer case and the vacuum release from the three port valve were connected so I separated them. Transfer case detent spring failed and the case ate it, took apart dug it out fixed it. Install drain plug; up to serial number 254845, tighten hexagonal drive drain plug to 54Nm (40 lb-ft), from serial number 254836, tighten 3/8" square drive drain plug to 28Nm (21 lb-ft) 5. You'll be. You can get it on Amazon for less than $15, see here for the original part. I didn't even (couldn't even) hit it hard because of thr lack of. Having done that, you now will set up your pump again, fill this case with 75w90 Mobil 1, and when full, replace the fill plug. Test loosening the fill plug first using the 18mm socket; sometimes these get stuck. I guess you can't overfill due to the position of the check/ fill plug. Not a whole lot of space back there. An oil suction gun will leave much of the oil in the axle; draining through the drain plug or lower bolt hole makes more sense. When you return, park on a level surface. Remove the spark plug cap by pulling it straight out. The goal here is to impact the plug with the chisel so that it will rotate in the proper direction, not to cut the plug out. Next use either needle nose or regular pliers and remove one of the two metal bands securing the Slip Yoke rubber boot, which is located on the slipyoke portion of the driveshaft. Dorman Products - 65339 : Oil Drain Plug Standard M22-1. if you can drop the transfer case, you can verify it is the transfer by rotating the input shaft, and watching the outputs, you can rotate the input and try and hold the outputs too to make sure they are still solid, all while shifting it through the ranges, if none of the outputs rotate with the input, something sheared, normally a key, sometimes the whole shaft. Both of the plugs in the 6MT seem to be made of aluminum. One of the bolt is stuck. Changing F/R Diff and Transfer Case Fluids 1995 4Runner You do not want to get the oil drained and find the fill plug is stuck and you can't get it out. When you return, park on a level surface. 1) As noted, this transfer case requires the patented AT-2 fluid that is only available from GM dealers and it is expensive. I also noticed that the transfer case's drain plug doesn't seem to have a magnet on it like the front diff. GM has issued a TSB #99-04-21-001 to discuss methods to remove stuck transfer case drain plug. 5 X 20 Bottom pan drain plug - Transfer case to. Position the drain pan under the transfer case. It seems to be stuck behind the handbrake drum. Use thermometer to check fluid temp ,once it reaches acceptable temp. 06" wide MTC-4210 SERIES TRANSFER CASE 4. Having done that, you now will set up your pump again, fill this case with 75w90 Mobil 1, and when full, replace the fill plug. Nissan technical service bulletins (TSBs) indicate that multiple 2000 to 2007 Xterra models suffer from manual transfer case problems. As I mentioned before, I have seen the NP231 Transfer Case come with 2 different types of fill and drain plugs. RELAY, GLOW PLUG. It looks like there is an 8 point torx bit (double square?) hole in the center of the fill cap that is very large. The little magnetic level, stuck to the frame, makes the job go a lot easier. Locate the transfer case plug. Remove the top filler plug, both should be filled to the level of the bottom of the fill hole. Front Diff and Transfer Case Oil Change Howto Compliments of jspadaro @ www. This should take about 2 quarts. I eventually rounded the corners off and tried a very tight pair of vise grips to no success. Make sure you chisel the plug and not the case. Any suggestions will help to. It was supplied in many GM, Ford, International and Dodge full-size trucks. It should be normally 1/16th or 1/8 above the hole. The drain plug is easy, but the fill plug is a real PITA to get to. The Jeep SR4 has a 23 spline output shaft for connecting to the transfer case input shaft. Front differential drain plug stuck on my 10m allen socket and new drain plug to replace it. 1987 - 1996 F150 & Larger F-Series Trucks - Transfer case filler hole plug rounded out - 1991 F150 302 4WD XLT I went to check the fluid level and add some if necessary to the transfer case and found out the square hole in the filler plug had been partly rounded out by whoever had the truck before me. Info - Same as the ATF remove the sump plug and drain the oil. Clean area around fluid drain plug, remove plug and discard the sealing washer. Failure of the rubber shifter sheet (bushing) is a common problem with Samurai’s. case so i can't drive it anywhere. square hole. Our certified mobile technicians come to you 7 days a week between 7 AM and 9 PM. Allow fluid to drain 5. xfer case plug stuck Thx. Not removed the drain plug yet. Remove the transmission oil fill plug and use a big screwdriver or small prybar to slide the gears back to a neutral position. Hi I need a little info. AutoZone Repair Guide for your Drive Train Transfer Case Transfer Case Removal & Installation. Fill plug is located on the center rear of the transfer case. The drain plug is easy, but the fill plug is a real PITA to get to. The last vehicle that I changed differential fluid on had to have the covers taken off which is more of a mess and pain then the easy way these ones are. The fill plug taked a 10mm hex head allen wrench. On my Jeep it was the diffs and transfer case. Be sure the old ring isn't stuck to the plug or the case. 00 core charge. If you can't get the fill plug out, then you don't want to proceed with draining the fluid; otherwise, you're stuck until you do get it out. It is also a good idea to be sure the fill plug will come out before removing the drain plug. As with other things, I like to tackle any sort of lift problem by first checking the possible causes that are No-Cost or Low-Cost items. Bolt the case into place and secure it. Working on a 2000 Dodge Durango with a nv242 aluminum transfer case. heating/cooling cycles should get them loose. If the fill plug is stuck and you drain the fluid, it leaves you with an immobile vehicle until the fill plug can be extracted. I have used a breaker bar when they are stuck before. Have sprayed Power Blaster on it for last 3 days, but no luck so far. Our oversized and rubber expanding oil drain plugs eliminate the need to replace the entire pan. Next I changed the oil in the transfer case. Remove the drain plug as well as the fill plug and drain the fluid into a pan. xfer case plug stuck Thx. Check your fluids. Re-install Plug. plug to check the transfer case about 2 quarts of trans fluid came out. 1987 Np231 Transfer Case Drain Plug Size Naxja ForumsFluid Fill Drain LocationsJeep Nv3550 Transmission Np231 Transfer Case ServiceJeep Nv3550 Transmission Np231 Transfer Case ServiceTransfercase Drain Fill Plug Leaking Jeep Cherokee ForumNp231 Drain Plug Stripped Best Photos PrimagemJeep Nv3550 Transmission Np231 Transfer Case ServiceNp231 Drain Plug Stripped Best Photos PrimagemJeep Nv3550. I have a 98 automatic with 4WD. Used heat (MAP/propane), pounded various size torx bits into it (T45, T47, T50 and T55; as you can see the hole is getting bigger and bigger). to 4-wheel drive using a Quadravan conversion with probably a “205” transfer case and with a adapter plate if needed, I would like to use a ZF 6-speed transmission if it will handle the torque. Place drain pan under transfer case and remove drain plug 2. This will be used to backup the socket for the next step. Ford F350 Factory Rebuilt Transfer Cases, we ship worldwide! To place an order please call the order desk at 763-425-7474 or toll free 1-800-444-0755. Check your fluids. First place an oil catch pan underneath the transfer case and make sure the oil will not spill onto the floor. Both take a 3/8" drive socket holder like a ratchet or bar. Messicks stocks nearly 70,000 different Case and New Holland Parts for the full line of equipment that they offer. 2nd Gen Ram Tech - Transfer case fill plug stripped - I decided today I should check/change the fluid in my t-case. I don't remember the fill plug for the rear, but I had a socket that fit it. I bought a torque ratchet at Harbor Freight tools to avoid this on anything. 2) Removed fill plug with 3/8" socket driver. Then pull off the vent line near the vacuum switch. A transfer case going dead is a like losing a part of your transmission. Try to move the shift pawl on the transfer case with a 9/16" wrench. The Advance Auto Parts core charge presented to you online today with your item is representative of the most common core charge. (or a Dana with threaded fill plugs in the covers) It's good to check the fluid level in the front diff, rear diff, and transfer case every oil change fill plugs on these aren't just for filling. Buy replacement parts for 1996 Toyota Tacoma at Go-Parts. Then remove fill plug to find the oil level has dropped (as oil has made it's way into the Crawl Box), and then fill until full a second time and then. If the rear end is locked up(100% rear wheel torque) which sounds like the case from what your stating that puts lots of stress on the PTU. Next use either needle nose or regular pliers and remove one of the two metal bands securing the Slip Yoke rubber boot, which is located on the slipyoke portion of the driveshaft. trasfer case will not switch into 4wd drive and I replaced the transfer case motor and now the car won't go into gear or show 2wd on the switch. I moved to the rear differential and noticed the fill plug was stripped already, but I still tried to get it out with 1/2" breaker and 3/8 adapter. my luck i'd end up punching a hole in the case. However, that is rounded off and still stuck tight. The transfer case is the heart of your 4WD Dodge Ram. I just did all fluids over the weekend and had the same problems, on the transfer case my drain plug was a hex bolt also, the aluminum to steel corroded pretty bad, I soaked with pb blaster used a small torch and with a hand 3/8 impact driver gave a few light taps with a hammer and it came loose with out further damage, same with the rear end drain plug. the fill plug is seized. Clean up any dirt and oil around the spark plug caps. If you can't get the fill plug out, then you don't want to proceed with draining the fluid; otherwise, you're stuck until you do get it out. It was kind of messed up when I started - someone had already partially stripped it and the plug is totally seized. Re: Need help with Diff/Transfer Case Fill/Drain plug sizes I know the front hex for the drain plug is a 10mm. I have used a breaker bar when they are stuck before. Transfer box filler plug stuck If I can't get it off can I just empty what's in there and re-fill from the top, just putting in the correct amount (2. Remove Fill Plug 3. OLD 1402700250 – A/T Plug Adapter (Conductor Plate Connector) This is the famous transmission plug that leaks oil and causes the majority of transmission problems (heart attacks). First, it helps with air flow in draining the fluid. Let’s say you removed the drain plug and the filler plug is stuck. The drain plug of course is at the bottom and the fill plug is generally half way up on the transfer case. Hello All, I thought I would do a quick writeup on how to drain and fill a 4r70w transmission. I will be changing it on a shorter interval going forward. You may end up getting stuck with a transfer case with no fluid. Call (877) 321-PART today for cheap/discount prices!. The drain plug is on the front of the transfer case and the fill plug is on the back side. That's the one. Buy ACDelco 15032997 GM Original Equipment Transfer Case Oil Fill Plug: Oil Drain Plugs - Amazon. Transfer case detent spring failed and the case ate it, took apart dug it out fixed it. How to remove a stuck transfer case drain plug GM has issued a TSB #99-04-21-001 to discuss methods to remove stuck transfer case drain plug. Install the fill plug. Remove rear crossmember and skid plate, if equipped. But as two separate cases on GM’s 4WD system reveal, these codes are not always 100% accurate. Howdy, Stranger! It looks like you're new here. The fill plug is towards. The label on the QT fluid bottle says to shake well. Hi I need a little info. The NP205 is a single piece cast iron case with helical gear driven transfer case with a 1. Transfer Case Removal. The plugs will be facing the rear differential. I used PB Blaster on it and soaked it overnight, it still won't budge. The vast majority of cases do this. After draining and re-installing the plug, refill the unit until oil starts to spill out the fill hole. Nothing under warranty or no help from Chrysler on the charges tho. Place drain pan under transfer case and remove drain plug 2. I had very little mung on the magnet from the drain plug on the transmission. use heat on the case AROUND the plug. Then remove fill plug to find the oil level has dropped (as oil has made it's way into the Crawl Box), and then fill until full a second time and then. Bolt is sitting almost flush with the transfer case which it shouldn't be. Remove the drain plug and allow the t/case to drain. But there is probably no fluid left in the transmission. When you return, park on a level surface. Several good ideas to try out. REMOVE TRANSFER CASE BREATHER PLUG (a) Using a screwdriver and a hammer, remove the breather plug from the case cover. Klune-V 4-to-1 Under-Drives Now Available With Ford 31-spline Input. I'm new to site and have a 2011 Enclave AWD. I am planning to change my transfer case oil on my Challenger M2 240 jet pump. Do not use an air impact, especially when putting them in you can damage the threads. Using a flashlight, check for oil at the fill plug hole. Sent from my HTC U11 using Tapatalk. Then use a pry bar to break the shift lever free. The case was dropped down onto some blocking, slid out from under the truck, and prepared for reinstallation. The most recently reported issues are listed below. Anyways, it was stripped, not entirely, but most of the way. tacomaworld. New question, Will the transmission fill plug part number 5140A fit?. One of our guys was a foreman at an FCA shop and he told me to split this connector and fill it with dilectric grease when I first brought my 15 SLT home. Stuck oil drain plug. I thought you just fill up, till the oil comes out the filler plug. Check for leaks, pray your computer doesnt go haywire like ours has and still is only shifting into first and second. Try to move the shift pawl on the transfer case with a 9/16" wrench. With these things in mind, does anyone have any ideas to try. You may end up getting stuck with a transfer case with no fluid. If the fill plug is stuck and you drain the fluid, it leaves you with an immobile vehicle until the fill plug can be extracted. OX Trax Locker. The one down low is the drain,while the top one is fill,of course. Taking apart the Drive Shaft leaves room to move the shifter bracket out of the way. I went to remove the fill plug, but it is stripped. The little magnetic level, stuck to the frame, makes the job go a lot easier. Remove Drain plug. The plug is flush with the transfer case housing. If you can change the rear diff, you should be able to do the front as well, along with the transfer case. So I swapped the big magnet plug into the diff, where the larger size sticks further into the circulating fluid then stuck the low profile unit into the drain on the case. Top the fluid up if needed. Dodge G360 5-Speed Parts. Then when you're ready to refill, you put that plug back in, and then there's your fill plug right there. I changed the transfer case fliuld out of my truck at 46K and the drain plug looked like that, also the fluid was fairly red. I own a 1999 Dodge Durango, V8 Mag. The NP205 gear driven transfer case is considered by many to be the king of bulletproof. brought to you by pro gear & transmission. Remove stuck transfer case drain plug How to remove a stuck transfer case drain plug. When full, the oil should be just below the top hole. I'm looking to change the oil in the gearbox of my 1999 s3 on 90k as the gearbox is stiff when cold and it didn't used to be. Any suggestions will help to. orlando, fl 32805. Re: transfer case drain and fill plugs stuck frozen i'd be nervous whacking it with an impact driver. Install drain plug; up to serial number 254845, tighten hexagonal drive drain plug to 54Nm (40 lb-ft), from serial number 254836, tighten 3/8" square drive drain plug to 28Nm (21 lb-ft) 5. Remove the top filler plug, both should be filled to the level of the bottom of the fill hole. Any advice or pics of the fill plug would be greatly appreciated. The quick lube place that has been servicing my 1999 Dodge Dakota pickup for quite some time recently stripped-out the fill plug in my NV242 transfer case. Loosening the filler plug first is a very smart move. Flushed Both Front and Rear Differentials and Fill (Mobile 1 75w90 and Updated Fill and Drain Plugs to 10mm Allen) Flushed Transfer Case and Fill (Mobile 1 75w90 and Updated Fill and Drain Plugs to 10mm Allen) At 138,122 Miles; October 19, 2016. The most annoying part was getting the oil into the fill plug on the rear diff. Kubota: RELAY, GLOW PLUG, Part # 16415-65600 Buy Online & Save. Once you get a slow trickle of oil out of the upper fill plug, reinstall the upper fill plug with a 10mm allen head socket. Thats why my transmission fluid was a little low about a month ago and had to add some. Rear Differential Fill bolt is stuck/seized Does anyone have any recommendations as to how I can get the rear differential fill bolt off my 2008 SR5v6 4x4? I have 35,000 on it and I went to do the rear differential and cannot for the life of me remove the 24mm fill bolt. This isn’t like the Talalay Latex which frequently has an airy and light feel. I changed front and rear differential oil, also the transfer case oil. Here is a picture from topside showing where the fill plugs are. It's dry so I'll see if it's quiet. for parts or service call: www. Can anyone explain WHY the differential fill plug has to be so tight?. My own method for leveling the car, before putting in the new GL5, Hypoid Gear Oil, in the Transfer Case. The T/C is the same but you have to make sure not to overfill it. The only way to check is to have the vehicle level and revove the transfer case fill plug, the level should be to the bottom of the fill hole, stick your little finger in the hole and if it comes. i would def check the fluid level. Install the transfer case drain plug. I searched around where I drove and did not find the drain plug. Bolt the case into place and secure it. Watch Doug, our Land Rover Master Technician, perform the differential, transfer case and axle oil service ( using our complete kit # DTCM600A) on a Discovery I, 1994 - 1999. GM has issued a TSB #99-04-21-001 to discuss methods to remove stuck transfer case drain plug. I stuck my finger in there and there is fluid right up to the bottom of the hole. Allow fluid to drain 5.