What did you do to your jimny today?

How big are your molegrips?  The filler plugs on the diffs were unshiftable until I attached really big molegrips and gave them a tap with a mallet, then they unscrewed surprisingly easily.  I smeared the new plugs with Ceratec brake grease so they will never rust!  The molegrips are better at applying pure torque - a square socket on a ratchet handle tends to apply a bending force as well, making the threads bind.

I had no problem with the diffs or the transfer box. My issue was the filler plug on the gearbox. The gap between the plug and the bodywork is very narrow so I can't use a ratchet to undo the plug. Also the female square hole has been rounded and feels like it has been attacked with a chisel or a centre punch meaning I cannot get the socket in to undo it. Also not enough sticking out to get a pair of molegrips on it to undo.
Not sure of my next move, probably have to take it to a garage.

You will find that someone has used a ratchet on it- there is room for just the ratchet handle but a ratchet is 3/8" which is only 9.5mm and rounds the hole.


I have one of those 10mm square adaptors with a hex body that a ratchet ring spanner will slip over for narrow spaces.

Order a new filler plug and then try undoing it with moles or a spanner on the 10mm square as suggested, or even just the ratchet pushed in the hole, if it goes round then you will have to carefully chisel the plug round.

I do have a new filler plug as I replaced all the plugs on the diffs etc. I have ordered a "L" Shape Radiator Spanner 10mm square which look like it will fit between the gap. Hopefully a combination of this and a pair of molegrips with a hammer on hand should free it. having a break from it today.
Thanks everyone for the advice given to me.

Searched all over the place today for my 1/2" to 3/8" socket adaptor. Wich on my Electric ratchet drill Does the filler plugs easy. None rounded still but remind me to buy something correct!

Found the adaptor in the middle of my work bench.
Also Searched for days for the transfer case axle seal.
Same place, on my work bench...

Got the transfer case back together with a New chain in it. The old one was at least 6-7mm longer said some eyeballing and a tape measure.

Also doing the clutch swapping to a centerforce enhanced Samurai clutch. Hoping it will do..

The usual problem is that the 10mm key won't go in because rust has reduced the size of the hole.  It fits into a new shiny one, but they don't stay like that in the UK, unless smeared with a temperature-resistant, waterproof grease.