seized fill plug

[bjd088]

The fill plug in my transfer case has been seized since I bought the truck. Now the transfer case is making a whining noise and heating up. Any ideas on how to get the plug out without damaging the transfer case or getting any metal shavings into it? (it's a 24mm plug)

[apummell]

tap socket on plug w hammer use air-gun

[bjd088]

The head is pretty well rounded from my previous attempt. I tried a socket but the head of the plug just flakes away.

[apummell]

ive used an air chisel before carefully chisel in the off direction once it moves it will usually come right out.

[bjd088]

I don't have air tools readily available, but I'll try a chisel and hammer this weekend. Thanks for the idea.