QX4 - T case fill plug stuck

[brickbox]

Trying to change out the t case fluid in my ‘02 QX4 with the all time AWD system.

I was able to break loose the drain plug, but the fill plug remains stubborn and won’t budge. I’m using a 3/8” ratchet with an extension. So it’s not the best of the fits.

Any recommendations on how to break it loose? Is the 3/8” the correct tool or is there a better and more snugger fitting tool that I can use without completing rounding out the fill plug?

[04pathse]

maybe try applying heat to the fill plug with a propane torch

[brickbox]

I was thinking about that. However, my apprehension is based on the case being aluminum, would I be screwing anything up with a propane torch?

I was thinking about driving it a few minutes to just let it warm up and then try to take it off before I got the propane torch out.

The 3/8” ratchet is the appropriate tool though?

[heavy hitter]

Always try removing the full plug first. That way if it doesn’t come out at least your t case isn’t empty

[macgiver]

Cooled down maybe better , I recently did mine and drain was tighter - the beast . I pre-spray blaster gentle hits with a large ball peen around circumference , more blaster , make coffee - drink coffee. Come back with a beater screw driver with keen edge ( I actually use sharp wood chisel) - Tap at angle the edge of plug in the LOOSE direction , around at different points is the key , and if no immediate results just repeat the blaster/hammer thing and try an actually SHARP chisel to GRAB/DIG the edge of the plug. Screw if you ding plug edge -can always buy another OR clean up with grinder - BUT YA GOTTA change yur FLUID!!!

[brickbox]

Hahaha, fair enough. I’ll give that a try tomorrow. I used my full body weight against the ratchet and the damn thing still did not budge
I’ll try the screw driver trick tomorrow and see if it works. Driving the truck around to warm it up didn’t do anything other than deform the plug itself when I used brute force

[heavy hitter]

Sometimes tightening it slightly more can help break it loose once you go the other direction again

[brickbox]

Wanted to close this thread out. I finally got it out yesterday. Torch did the job. The liquid was just black and disgusting.
Interestingly, I tried the tighten slightly advice and it still didn't budge. I guess 19 years of galvanic corrosion will do that....

[macgiver]

All due respect - nineteen years of not doing regular maint. Another good reason to do often
Heavy Grease/anti seize threads when re-installing virtually prevents this too, helps seal ,necessitating less torque on the plug too.

[brickbox]

Yep, the PO never touched the T-case, ever!!
The trans fluid was flushed once around 85-90K and the diff fluids were changed every 50K, but the T case had that wonderful original factory fluid

[Frank01pathfinder]

Is fluid transfer pump needed to fill the transfer case?

Also did you guys use atf or gear oil?
Thank you

[nickelghandi]

Is fluid transfer pump needed to fill the transfer case?

Also did you guys use atf or gear oil?
Thank you

No it is not. Loosen or remove the fill bold. Remove the drain bolt. Drain. Fill with ATF.

You are popping up everywhere. You might want to check this thread: pathfinder-qx4-general-information-and-q-a-t549378.html

[macgiver]

ATF in a transfer case is definitely the exception , what's the "manual" say again ?? Bet Mob 1 75/90 better if GL4 /GL5 WAS specified ???

[nickelghandi]

From my previously specified link regarding the VQ35DE:

Transfer fluid:
Part-time 4WD model: 2.32 quarts
Use Nissan Matic D or equivalent Dexron III/Mercon, or GL-4 gear oil. ATF is used in the factory. Do not mix ATF and gear oil in the transfer case.
All-mode 4WD model: 3.17 quarts
Use Nissan Matic D or equivalent Dexron III/Mercon. ATF is used in the factory.

You can check the FSM, and many other online resources. ATF is used in the transfer case for all 4WD 1996 to 2004 Pathfinders. The fluid capacities vary between the VG33 and the VQ35 but the fluid remains the same.

[brickbox]

I used one of those squeeze bottle things for getting the fluid into the T-case.
And yes, it Nissan D Matic or equivalent (I used the Valvoline Maxlife stuff - same as what's in the trans on my QX4 and I'm quite happy)

[Bigedmustafa]

Hey all. New to the QX4 and as a result this robust forum. So excuse or point me if I am in wrong place.
Went to do fluids and immediately noticed a broken of part of a 3/8 inch ratchet inside the T case drain plug. Plug is mangled.
I will get it out one way or another however am curious as to a replacement plug?
Anyone have the thread specs on the these plugs? Suitable substitute?
Any help is appreciated

[Pathyj1]

Why all this talk about 3/8” ratchet? I bought a 13mm square socket for a 1/2” drive and it fit perfectly. I’ve seen talk of using a 1/2” drive itself but that is a tad too small and will deform the plug

[mdmellott]

Anyone have the thread specs on the these plugs? Suitable substitute?
Any help is appreciated

Can't find the thread specs. It's the same as the fill plug so you could take that one out and measure the specs or match it up with aftermarket plugs at a auto parts store. It is a metric size so good luck on that. Auto salvage yards are a possibility but kind of a pain for this little thing.

I did find that Amayama Trading in Japan may still have the original new part, They have a "Make Inquiry" button on their website so you can ask them regarding availability of part number 33312-23U0A. Their price is $1 plus $16.51 for shipping to the USA. https://www.amayama.com/en/part/nissan/3331223u0a