98 Tahoe Tcase

[Tony Viv]

Hello All,
Im new to the group but have read almost all posts and have found a wealth of information so far.
Now though I ask for your advice I think Im in a real pickle.

I blew out a ujoint the other day, no biggie. Figure while Ive got the Tahoe up off the ground and its now out of warrenty, Id better do some maintence. Change diff lube and change the Tcase over to the new blue fluid. Didnt get to the diffs yet.
Went to change Tcase though, and NO way was the fill plug coming loose. Ive never seen something so tight. I ended up on it so hard its almost rounded out. Why such a small 1/4 drive plug. Least the diffs are 3/8 drive. Im glad I went to the fill before the drain.
Well any ideas, how am I going to get it off now?? It wont take much more pressure before it rounds the rest of the way.
My first thought was to JB weld a cheap square bit or extention to it.
Who knows
Help
Tony
98 Tahoe z71

[1Bradymichael]

I had the EXACT same problem a few years back on my '88 1/2 ton. New Proccess builds a good tc but why can't they put a big nut on the plug?#@! What I ended up doing was taking a die grinder and grinding some material out of the center, and then I took a pipe plug, JB'd it after it fit nicely in the hole, and the next day it came out after some coaxing. I used a mallet and tapped a little gently at first to break the plug loose. Hope this helps and good luck.
Mike