I know this one has been discussed before, but I'm at my wits end on this.
Relevant info:
1998 Suburban K2500, >8600 GWVR, 4L80 trans, NP246 diff
I have the old style (1/4" drive aluminum fill plug), which I've managed to strip round. I spend the day today trying to get it out, only to make the hole bigger and bigger.
Here's what I've done:
Pulled the torsion bars our, and removed the torsion bar crossmember that sits just rearward (about an inch or two) of the transfer case to get a bit more access to the plug. 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). As far as extractors, I tried a 1/4" pipe nipple extractor (its the least tapered one I could find). My other extractors had too much of a taper to ever get a bite. Finally, cut my biggest extractor in half with a grinding wheel to get as much in contact with the hole... still nothing. The old plug metal is so soft, nothing can get a bite into it. I tried spraying with penetrating oil, but the entire thing is vertical, most just runs off. I've thought of the old "make a little dam" out of putty trick to hold some up there; I'm not sure it's worth it considering I can't get a bit. I'd be suprised if I ever got more the 30 foot pound on it (calibrated elbow).
Right now there's about a 3/8" hole about 1/4" deep in the plug.
I'd prefer not to have to pull the entire transfer case off. I could probably drill it out as it sits, I'm mostly worried about the metal shavings that will end up inside.
Any thoughts, suggestions, encouragement, or "you're screwed" is encouraged. I'm not really screwed though... the t-case runs just fine; I'd just prefer not to have to slap the "run till fail" sticker on it.
Relevant info:
1998 Suburban K2500, >8600 GWVR, 4L80 trans, NP246 diff
I have the old style (1/4" drive aluminum fill plug), which I've managed to strip round. I spend the day today trying to get it out, only to make the hole bigger and bigger.
Here's what I've done:
Pulled the torsion bars our, and removed the torsion bar crossmember that sits just rearward (about an inch or two) of the transfer case to get a bit more access to the plug. 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). As far as extractors, I tried a 1/4" pipe nipple extractor (its the least tapered one I could find). My other extractors had too much of a taper to ever get a bite. Finally, cut my biggest extractor in half with a grinding wheel to get as much in contact with the hole... still nothing. The old plug metal is so soft, nothing can get a bite into it. I tried spraying with penetrating oil, but the entire thing is vertical, most just runs off. I've thought of the old "make a little dam" out of putty trick to hold some up there; I'm not sure it's worth it considering I can't get a bit. I'd be suprised if I ever got more the 30 foot pound on it (calibrated elbow).
Right now there's about a 3/8" hole about 1/4" deep in the plug.
I'd prefer not to have to pull the entire transfer case off. I could probably drill it out as it sits, I'm mostly worried about the metal shavings that will end up inside.
Any thoughts, suggestions, encouragement, or "you're screwed" is encouraged. I'm not really screwed though... the t-case runs just fine; I'd just prefer not to have to slap the "run till fail" sticker on it.