Rounded out fill on transfer case - Chevy TrailBlazer, TrailBlazer SS and GMC Envoy Forum



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Go Back   Chevy TrailBlazer, TrailBlazer SS and GMC Envoy Forum > 2002 - 2009 TrailBlazer/Envoy Tech > 02-09 Vortec 5.3L V8 Engine and Drivetrain > 4x4 Drivetrain

4x4 Drivetrain 4x4 Repairs & Problems

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  #1  
Old 03-31-2018, 04:14 PM
06denaliman 06denaliman is offline
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Rounded out fill on transfer case

Well my new to me 06 envoy denali. Was doing fluid changes. Started at the front did engine oil, front dif and was then going to transfer case. Tried taking fill plug out and the hex head rounded out. My question is there another place i could fill it if i manage to get drain plug out? Saw a sensor near top of it was thinking i could fill there?


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Old 03-31-2018, 04:57 PM
miketexas miketexas is offline
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vice grips
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Old 03-31-2018, 05:01 PM
06denaliman 06denaliman is offline
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Tried with no success. Is there another spot i could fill it? Didnt drain it yet but if i do i wana way to put fluid back in


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Old 03-31-2018, 06:05 PM
miketexas miketexas is offline
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I suppose you could fill it from the sensor, I don't really know though.
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Old 04-01-2018, 10:09 AM
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How did you ever manage to round the hex head? Oh, never mind. 10mm is kinda close to 7/16.

Problem is how are you going to check the level when you are done? That plug has to come out. If vice grips don't work with a cheater bar on the handle, then it is time to start grinding for another wrench. At that point I would carefully grind two flat surfaces for an open end wrench. PLEASE use plenty of Liquid Wrench.
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Old 04-01-2018, 12:22 PM
06denaliman 06denaliman is offline
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Acctually not that uncommon to round it out considering its flush mount and a hex head and if its in there good its not a hard thing to do.


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Old 04-01-2018, 03:50 PM
06denaliman 06denaliman is offline
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Plus id just put in amount of fluid the call for and it would be fine.


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Old 04-01-2018, 05:10 PM
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Maybe try heating up the area around the plug with torch and see if a 11mm (or anything slightly larger than 10 mm) wrench can be jammed in.
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Old 04-01-2018, 05:50 PM
06denaliman 06denaliman is offline
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Originally Posted by EnvoyBoy2004 View Post
Maybe try heating up the area around the plug with torch and see if a 11mm (or anything slightly larger than 10 mm) wrench can be jammed in.


As unfortunate as this is i tried that too. If i could just get old fluid out and new in id be good for 50k miles and worry bout it later.


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Old 05-05-2018, 03:12 PM
06denaliman 06denaliman is offline
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I ended up just payin shop 80 bucks to get plugs out and exchange fluid and put new plug back in. Was easier and faster.


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