Stripped transfer case drain plug

[basic]

Well, it happened. Stripped the drain plug on the transfer case. Fill plug came out fine. After heat, PB blaster, tapping - thought it was coming out..but stripped instead.

Any tips/tricks? First instinct is order an ez-out that will fit nicely in the nice round hole that's there now. If that doesn't work...weld a socket to it?

Really need to remove it to drain fluid as I got some water in the transfer case fluid. I know...I know....

 

[Modoc Guy]

Trying to weld something to it would be my choice, but that’s gonna be tough in the Jeep.

I wouldn’t use a socket, I’d use a stubby extension so I could get a breaker bar or impact gun on it.

And the stubby extension will give you 4 spots on the plug to get some good tacks.

 

[bromel]

I just went through this. Eventually hammered a T-55 or T-60 torx in there; I forget which. You might have to shave the metal a bit.

 

[Wtrask]

Get it red hot then let it cool and spray it with some pb blaster. Then hammer a larger torx bit into it. Repeat til it works.

 

[Vinman]

I held a 1/2 bolt in the stripped hole and welded it in place. The heat from welding loosened it right up and came out easily

Edit: found the pics

 

[basic]

Well, update here. Tried torx first. The t55 is about the same size as the stripped m10 hex, so it wasn't quite big enough. T60 was slightly too big, and I wasn't able to get it deep enough to bite well and just stripped it more.
Ended up welding a cheap 3" long 3/8" extension into the hole and was able to get it out. Thanks for the help all!