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Stripped drain plug for transfer box. Ideas?
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DVD
 


Member Since: 06 May 2012
Location: Arizona
Posts: 48

United States 2005 Discovery 3 4.4 V8 HSE Auto Tonga GreenDiscovery 3

Sorry to keep dribbling this along. I'm lucky that I work from home, so it's not a big impact to have the vehicle sit for a few days, and it lets me think it through.
A new clue. I carefully measured the original plug and the interior sleeve.
The plug extends to the top of the openings.

It would entirely block the openings when inserted, so I conclude that the openings are not operationally functional.
The openings would, however, allow greater draining, so I think that's the purpose.

It might be coincidence that the plug extends exactly that far - drain plug and fill plug are exactly the same.
Armed with this information, the plug with integrated drain valve (which has the same threading height as the original plug) would be counter-productive because it would block the openings and not allow totally draining.
I'm going back to the plan of using a longer plug that will extend into the virgin threads above the collars. I don't think it's necessary to drill out the new bolt because the original one obscured the openings anyhow.
The only mystery is why the case internals are threaded above where they need to be?
And of course, let me know if something sounds terribly wrong in my theory Very Happy
  
Post #14381016th Mar 2015 5:06 am
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DVD
 


Member Since: 06 May 2012
Location: Arizona
Posts: 48

United States 2005 Discovery 3 4.4 V8 HSE Auto Tonga GreenDiscovery 3

Here's the 1 yr follow-up. I found a replacement screw that fit well (socket head so it doesn't protrude). The bolt has the following dimensions: M16 Thread, 30mm Long, 1.5mm Pitch (here's the link http://www.mcmaster.com/#96144A331).
The screw was a little longer than ideal, so I cut down the length so that it engaged with the untouched threads but didn't go beyond them into the reservoir.
One year later, it's holding tight and no drips.
  
Post #16193472nd Mar 2016 8:55 pm
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Ginner
 


Member Since: 28 May 2014
Location: Cheshire
Posts: 189

United Kingdom 2005 Discovery 3 4.4 V8 HSE Auto Zambezi SilverDiscovery 3

Exactly the same happened to me, I ended up helicoiling it....

J
  
Post #16193652nd Mar 2016 9:28 pm
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mek
 


Member Since: 18 Mar 2015
Location: Zurich
Posts: 445

Switzerland 2006 Discovery 3 TDV6 Base 5 Seat Manual Tonga GreenDiscovery 3

Hi

Thanks for your reply - I have ordered an M16 bolt, fine 1.5 pitch, 25mm long (you said you cut down your 30mm bolt) for a few quid off eBay. So I should have everything I might need when I drain the Transfer box again

Andy
  
Post #16210546th Mar 2016 11:34 am
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Heliart
 


Member Since: 05 Aug 2017
Location: Wiltshire
Posts: 25

United Kingdom 

Sorry to revive an old thread.
But just serviced my recently purchased 2008 D3.
The transfer box drain plug certainly has thread issues. I can tighten the plug, and it's not leaking but I can't quite torque it to 22NM.

I'm thinking this kit might be a very good solution:-
http://www.ebay.co.uk/itm/M17-x-1-5-Oil-Pa...1050297655

Steve
  
Post #18659988th Oct 2017 7:32 am
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DVD
 


Member Since: 06 May 2012
Location: Arizona
Posts: 48

United States 2005 Discovery 3 4.4 V8 HSE Auto Tonga GreenDiscovery 3

FYI, 2 1/2 yrs later and a couple fluid changes later, the replacement bolt on mine is doing fine.
I had my vehicle on stands this weekend for another project, and checked the transfer case replacement drain plug/bolt, and it's dry and fine.

The longer bolt seems to make all the difference. There's plenty of tapped interior, just need the longer bolt.
  
Post #18663859th Oct 2017 2:40 am
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