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General Forestry => General Board => Topic started by: Delawhere Jack on June 21, 2014, 05:09:40 PM

Title: F250 transfer case odd sized fill - drain plugs?
Post by: Delawhere Jack on June 21, 2014, 05:09:40 PM
The drain and fill plugs on the transfer case of my '88 F250 have a square recess. I assumed that a 1/2" ratchet drive extension would fit to remove them, but it is too large. 3/8" is too small.

I think the previous owner may have replaced the plugs since they look fairly shiny. It's a BW 1356 case, and I believe the fittings are 3/4" NPT. I'm not finding any info on what sort of wrench will fit them. Any suggestions?
Title: Re: F250 transfer case odd sized fill - drain plugs?
Post by: yukon cornelius on June 21, 2014, 06:41:54 PM
my78 is 1/2 and my 93 was 1/2" I couldn't imagine what else it would be, I did have trouble with one extension I had that the spring and ball wouldn't let it fit. I tried another and it fit fine. good luck!
Title: Re: F250 transfer case odd sized fill - drain plugs?
Post by: POSTON WIDEHEAD on June 21, 2014, 06:59:03 PM
On another application...I took a bigger wrench and ground the sides down to make it fit the plug. It works great.
Title: Re: F250 transfer case odd sized fill - drain plugs?
Post by: Delawhere Jack on June 21, 2014, 07:51:26 PM
Quote from: POSTONLT40HD on June 21, 2014, 06:59:03 PM
On another application...I took a bigger wrench and ground the sides down to make it fit the plug. It works great.

That's what I'll probably end up doing. It just seems odd. I doubt that it's metric (12mm?). Just wondering if it was some sort of plumbing standard size.
Title: Re: F250 transfer case odd sized fill - drain plugs?
Post by: sandhills on June 22, 2014, 09:55:31 AM
That seems very odd, I'd like to know how you solve it sorry I can't help more.
Title: Re: F250 transfer case odd sized fill - drain plugs?
Post by: Delawhere Jack on June 22, 2014, 04:51:50 PM
Everyone I talked to was stumped. The guy at NAPA suggested that some machine shops use odd sized plugs in engine rebuilds, in places like the oil galley between cylinder banks.

Anyway, the square recess measured .425" across the top and about .410 across at the bottom. They are aluminum. I got a short 1/2" socket extension and ground it to fit.

The WM got a shower in ATF from the leaking seal on the rear output shaft, but all is well now.

Ole Hee-Haul keeps me busy with repairs, but I grin and bear it when I see the price of new trucks.  :o



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