Transfer Case threads stripped '05

Arrgghhh. I decided to spend an hour or two Christmas eve day changing my engine, transmission (5 spd MUA) and transfer case.

Engine no problem.

Transfer case. Took the drain and filler bolts off, let it drain etc. Put drain plug back on, big steel 15/16 bolt. Noticed that it didn't really bind up, so I stopped and pulled it out. Hmm bolt looks OK. Looked in threads of case, put my finger in and pulled out a couple coils of thread metal. Oh no! I was pretty sure I didn't do it when I put the bolt on, because I screwed it in by hand and then used my 3/8" (not even 1/2") driver to tighten, except it didn't.

I looked at the fill plug and threads, same thing! Now I know it wasn't me since I only removed the bolt so far.

So please help.

What does one do when the threads are stripped in the transfer case? They are pretty badly stripped, both drain and fill. The bolts are in, but I can barely get them any tighter than finger tight.

How high is the pressure in there? Is finger tight enough? Loctite? Cut some more threads for a larger bolt?

Please help me, I have passed my own experience level now.....

Andrew

Couple of choices here, they make some emergency plugs that are rubber and expand in the hole as you tighten it. Easy and fairly permenant.

My suggestion, get two oversized plug bolts that will cut new threads at your local parts store. Cut the new threads and run some oil through the case to get the gunk/metal out.

Good luck,
Joe

Thanks. I will be looking into options today. I have been using the car. I used some blue RTV to cost the bolt threads and threaded them in as tight as I could get them without loosening them again.

I will remove the fill plug today and see how tight it is with the gasket maker (blue RTV). If it is not tight enough, I might try one of your suggestions. Not sure how easy it is to get a larger plug.

The ones on the Rodeo have a conical bolt hole for a rubber "O" ring that sits at the head of the screw.

Andrew