Heating Metal to Release Filler Plug

Danno1 · Oct 14, 2011

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Aluminum grows faster than steel when heated (has a greater CTE). Heat the aluminum and turn the plug while everything's hot.

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RoyJackson · Oct 14, 2011

Danno1 said:
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Aluminum grows faster than steel when heated (has a greater CTE). Heat the aluminum and turn the plug while everything's hot.

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Yeah, but when holes are involved, expansion may not work to one's advantage.

LD1 · Oct 14, 2011

RoyJackson said:
Yeah, but when holes are involved, expansion may not work to one's advantage.

Bingo:thumbsup:

Shield Arc · Oct 14, 2011

I've had good luck removing bolts, and plugs from aluminum with a heat gun, and a spray bottle of water. Find a short piece of pipe that will just fit over the bolt / plug. Heat the aluminum around the bolt / plug real good, hold the short piece of pipe over the bolt / plug and spray water into the pipe. Drop the piece of pipe, and remove the bolt / plug with a wrench.

Beltzington · Oct 15, 2011

Tried the wax, hopeful as it appeared it wicked into the treads. No Joy, followed up with more heat, slotting with a grinder, cold chisel, hammer, select profanity, beer and I am going to have to remove the transfer case. Thanks for the help.

Shield Arc · Oct 15, 2011

What about securing a magnet real close to the pug, and drilling it out? Step drill it until you can cave it in with a cold chisel, and retap the threads if necessary.

Beltzington · Oct 15, 2011

This all started with driveline noise, I might continue to try and resolve the problem on the Jeep if I didn't think the TC was bad. Should junk the vehicle but it has been my baby for 15 years and can't part with it just yet.

yomax4 · Oct 15, 2011

Sometimes heating is not the way. See if your local welding supply will sell you a little Liquid Nitrogen. Dangerous stuff but if handled carefully it works wonders. Dribble a little on the area that you are having trouble with. It freezes so very cold and everything contracts so much that it often makes bolt removal as easy as the day it was installed. I always drop my bearing races in N2 before installing. Same with shafts. Dip in N2 and the bearings slide right on. Just another way to try.