Gaining familiarity with my '05 included D&Fing my transfer case. My Ranger has its damper.

For those who don't know, the damper is a counterweight attached to the rear of the transfer case and has to be removed to access the drain plug.

After cracking the 4 bolts loose I squirted on some PB Blaster. Of course on of the bolts broke. The bit of stud showing isn't long enough to grab.

I've been applying PB and Silikroil alternatively and letting them sit. I cut a slot into the stud. My cut included a bit of the bolt's boss. The boss sticks out quite a bit.

A straight slot screwdriver fits the slot but I cannot get 1º of turn out of it. MAN, is that bolt in there!

What's angering is that it's a steel bolt into an aluminum TC and is expected to be out in the rain and salt. 15 years of electrolytic action

The assemblers absolutely should have slathered Anti-Seize on those parts.

I have cleaned out the other 3 holes with an 8 X 1.25 tap.

Do I live with only 3 bolts holding my damper in place or do I hit the boss with heat? ...or do I drill it out and retap?

 

If its just the counterweight and not a mount, send it.

 

"send it", where?