Rusted out 3/8″ female plug

[Travis]

I have a 93 Ford Ranger 4×4 with a Borg Warner 1354 electronic transfer case. I was trying to change the fluid in it, but the plugs are completely rounded out. A 3/8″ ratchet head will just spin in them. I’ve tried using the chisel and hammer and soaking them with pb blaster and seafoam deep creep, but nothing seems to work. I don’t want to heat them because they are close to the shift motor and gas tank and because the plugs are steel and the transfer case is an aluminum alloy. I don’t have any air tools to use. Any suggestions to get them out?

Topic

[Charles]

IF the hole is not round but just too large for the 3/8″ rachet perhaps you can add a shim to two sides of the hole to tighten the fit. Hacksaw blade comes to mind.

[Daniel]

You could try hammering a torx bit into the hole or pick up a set of “easy-out” bits. Good luck

[johnzcarz]

One thing that comes to mind is using one of these extractors. They are made by Irwin (as in Vice-Grips).

[Travis]

I’ll see if I can find a easy out that fits. Looks like the best option unless my T50 fits with a little negotiation with the BFH. Thanks for the suggestions.

[EricTheCarGuy]

I too have hammered on the next size to deal with a situation like this but my air hammer gets me out of jams like this all the time. Sometimes the right tool makes all the difference. Anyway you might be able to borrow one from someone?

[Author]

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