Topic: T-case drain plug problem...

[wa4x4]

Well, I am helping my buddy fix his brother's 81 toyota 4x4 at school. We have the tranny and t-case out of the truck and they are now on a table. The tranny drained perfectly, but the t-case drain plug looked like the PO had tried to unscrew it with pliers too many times. Very stripped, so much though that we took it out with the fluid in and decided to wait to get it out. Now that it is out and on a table, what is the best way to get this stripped drain plug out? It's not too urgent right now, we are going to tear apart the tranny first to find the true problems. So far the bearing on the input has broken the metal that is supposed to keep the balls from moving around the bearing too much. Those metal "walls" stuck out, hit the main gear on the input and shaved off several teeth on the main gear, but that is all we have found so far. A worn out clutch and a messed up gear/bearing.

[BLACKDOG]

weld a nut to it, and try to unscrew it

[wa4x4 [OP]]

At school we have no access to a welder....
I guess tomorrow our task is to take the T-case away from the tranny, take it home, and get a nut welded onto the plug.

[MiniSimp]

Grab a 12 point socket that almost fits on it and hammer it on, then remove.

[wa4x4 [OP]]

Craftsman tech right there!!

I will try that tomorrow...might be worth it to take in my personal Craftsman instead of the tools I rely on daily in there. Snap-On guy doesn't warranty against misuse!

[BLACKDOG]

what about just taking off the shifter and turning it upside down, since you already have it out of the truck?

[wa4x4 [OP]]

We have the shifter out, so wow...guess that would be super easy. I didn't see much fluid lookin down there, but then again that was the first time I had seen the Toyota shift rails in person so I was trying to picture how exactly everything works. That's what I do though.