Yeah I decided to let it sit overnight to figure out the best course of action. It occurred to me to just pop it from the inside once I got the cover off

Unfortunately I'm an idiot and managed to break off some of the bolt heads (upside down + solvent fumes = overtightened the bolts thinking I was loosening them). So my next step is to try to extract them with a left handed drill bit (DOH!).

 

Also, I'm going to use ultra blue RTV (it's what the guy at carquest recommended).

The process as I understand it: thoroughly clean both surfaces, apply a thin line of the RTV sealant to both surfaces, pop the cover back on + replace bolts to near-tight, let it sit for an hour, fully tighten them and then fill with gear oil.

I'll let y'all know how it goes :-D

 

-- double post --

 

Oh..Sh#it! Didn't mention, "Lefty Lucy!". That's not good. Might be better if they where bigger. You might find them surprisingly loose, (now). If there is any thing at all try pushing on the little stub with a screwdriver to turn it. Or regular pliers if there is anything to grip. Don't know your situation but jacking the Jeep and letting the axle pull the springs down will give you more clearance, (obviously). I would drill it with a normal bit and use an easy-out. (a little deal you tap into the hole that grips to extract the remainder). You can dull a bit in an instant by going too fast. Real slow with oil, "let" the bit work. S#*IT !

**A cutting wheel on a dremmel could make a screwdriver slot**

 

Ya it's slow going, but I managed to get 2 out. The first one grabbed after about a quarter inch, the other I drilled all the way through the bolt and had to pop in the screw extractor.

10 minutes of idiocy has gotten me hours of cleaning up my mess

Thanks for the advice.

 

A little late to this party but i changed from rtv to the lubelocker gaskets. much nicer to clean things up and re-install no mess.

 

Who said "the Devil is in the details?" Waaaay understated. Needs an exponent.
Once swapped a Ford engine in about 1/2 a day. Then spent 1/2 that time hooking up the solenoid wire. Ya sort of freeze then vibrate like a tuning fork. At least you're making progress, beats the alternative!

 

Update: Got the cover off, but the plug wouldn't even pop through, so I had to pull it thru to the inside. Got it a little deformed in the process, but luckily the auto parts store had a replacement :-D

Seal seems to be holding, no leaks so far.

Thanks for all the input everyone

~~tetrad