bloody tc fill plug wont come out

jeudi 3 juillet 2014

Hello I have a problem.



I have a 249 transfer case and it has a slow drip, i went to remove the fill plug and it is a shallow 10mm female allen drive on a huge plug that must be close to 25mm in diameter.



I first tried a 3/8 drive 10mm allen socket and could not budge it with an 18" 1/2 drive breaker bar.



I then tried a 1/2 impact wrench at about 220 ft-lb and it still wont move. I think thats all the 3/8 drive can take. Also I was troubled to noticed the hex socket is ever so slightly looser in the plug now. So I am treading a little more carefully.



I'm curious, what others have done here.



My next thought, I ordered a honking 1/2" drive 10mm allen, heat the plug with a propane torch and quench with wd40. Then blast away at it with a 600 ft-lb impact, and pray I dont break the allen key or worse round out the socket?




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