Frozen trans drain plug on Boxer

My new clutch is working and installed but I need to refill the gearbox in my Boxer from draining the transfer case but the overfill plug is stuck, the bolt has disintegrated to rounded corners, I have tried vice grips with a pipe for leverage with no luck either as they are rounding the plug more.

So I guess the next step is heat with a propane torch, I would heat the area surrounding the bolt correct so it will expand and try the vice grips again? Any concerns for trans case damage by heating or anyone have a better idea?
Also an impact wrench will not work as its in a tight spot on a open end or vice grip tool will fit

Thanks

Man, these things are always hard to remove...the last two times I opened mine it was very hard to remove (328), so the most recent time, I put a bit of anti-seize on the threads and was esp. careful not to over torque.....

Dave

While I'm not a big fan of heating fasteners or plugs to remove them, sometimes it's the only way. I worry about oil on the back side as a high enough heat will break it down leaving some crud behind. Having said that you could probably heat up the housing to maybe 240 F before the oil residue begin to form. This is higher than the boiling point of water so a drop of water in the heated surface will boil when you get close. Aluminum expands about twice as much as cast iron and about 50% more than steel, for a given temperature increase. Ideally, heat the casting as much as you dare and chill the plug if possible, perhaps with an ice cube (try not to let water drip down onto the casting if possible as this will affect the casting temperature a little), then try to remove it. If you can get the temperatures different enough, the plug should break free. I also use anti-sieze on these plugs.

Thanks for the replies Bill and Dave

Finally got it out, I heated the plug with a propane torch several times then sprayed it with water to shock the bolt, then finally heated around the plug while spraying with water outside the plug area to keep it cool and heat from spreading, took a good quality pair of vice grips with a small cheater pipe on it and it finally broke free, this took several tries.

Interesting at least a quart of trans fluid came out , my assumption is this bolt has rarely if ever been off, the so called shops that serviced this car just drained the fluid and filled to book spec without properly checking the level

Hi.........

Next time, try cooling the plug with dry ice. Use thick gloves!! Might contract a sufficient amount to facilitate removal.

No heat and no burnt oil.

Frank.......23005
www.masiarz.net/bb_resource

Thanks Frank

Would keep it in mind if something like this happens again