Went under to replace my 242 transfer case fluid today for the first time. Fill plug (top) came out fine. But the hole in the drain plug (bottom) where the hex bit goes was stripped out round. I was able to siphon more than a quart of fluid through the fill plug, so I was able to put in a good amount of fresh fluid and feel okay for now. But someday I’m gonna wanna get that drain plug out. Any ideas? Thanks.

 

Take the next larger size from the :"other set", metric if the plug is standard, standard if the plug is metric, and hammer it into the hex. A few tack welds to hold it in would really do the trick, but not needed.

To ease getting it out, apply heat to the aluminum case around the plug. It will expand more than the steel plug, making it much easier to get out...

 

Thanks!