Bought the jeep three months ago and found my first surprise.. I've read all of the threads here to find out the tricks I didn't think of to get this darn thing out. What you see is pretty much how i found it with a few dings from attempting to tap it out (that small weld spot was where i was tapping..) From the looks of it someone tried to stick weld a bolt on there but failed...

This is what I've tried
1. easy-out tool, my set doesn't have the exact fit without drilling the hole out a bit.. made me worried so I didn't drill it out..
2. Heat with torch tap, heat, tap, heat, tap, heat, tap....
3. Froze with dry ice, tap, ice, tap, ice, tap...
4. torx socket hammered in.. could not get any grip on side..
5. larger allen size.. i believe a 12mm was what i used.. could not get enough grip as well..
6. jb weld sucks but i tried it.. extra strength, 36 hours allowed to cure just to take that out of the equation.. gave me about 50lbs of torque and it then it broke out.. fail!

Are my final options to weld a bolt on there? It makes me worried to heat the aluminum up that much (I've heard horror stories of it literally welding the bolt straight to the case).. I can't weld so ill have to find someone who can.. If I have to pay for it, would it be cheaper to buy a new transfer case cover? (it looks like i can get a new one for about $90, ill try junkyard first if i go that direction)? It is an np231. also, if i go the new cover direction, is it an easy job to replace the cover?

Thanks everyone,
Dave
Denver, Colorado

 

ouch. I'd save the hassle and headaches and get a new cover. bolts like that are nobody's friend...why in the hell would somebody weld that???

 

it goes against everything in my signature but go punch the previous owner in the face.

 

haha.. that's kinda how I feel ever time I get under and look.. Do you know if the case cover swap is an easy job?