Ok I exhausted about everything I could try getting the transfer case filler bolt off. The PO stripped the bolt out so I tried getting a pipe wrench on there with heat (from a little propane torch)to no avail. I also tried hammering a wrong sized socket on there and use a breaker bar. That also didnt work. Next I tried the world's largest pliers with no success.....

I know the little propane torch is not putting out much heat so I held it on there all the while tapping the head with a small hammer. I'm about to go pay someone to remove it for me unless you guys have more suggestions.

~Jake

weld a socket to it.

I once used an air hammer with a wedge type chisel to break a differential filler plug loose. One thing though, you will need to get a new filler plug from the dealer

both of the ideas above are the best way ive don them both!

I usually weld an old nut to the head of the plug then use that to remove the old plug. Frequently the heat of welding is all it takes to loosen up the plug. Replace it with one of the socket head plugs.

You could use a Dremel-type tool to cut a slot into the bolt head, then use a B.F. scewdriver to remove it.

Thanks for the suggestions. I will pick up an air chisel tonight and have at it!!

Also, use the small torch to heat up the transfer case around the bolt, and not necessarily the bolt itself. What will happen (hopefully) is that the heated metal of the transfer case will expand (in micro-millimeters, anyway) around the bolt and remove some of the friction from the threads. That, combined with a hammer and chisel (or air, if you prefer) might do it.

the welding stuff is the best way if you have a welder.
I didn't, and had a recent similar problem with my transmission fill plug, so I ended up drilling it and using a bolt extractor.

It is OK if you chisel off a chunk or two while you try to back it off. It seals around the edges, usually, you get enough of the edges off and it screws right out. get a new plug while you are out air tool shopping. I too like the socket head plugs.