T-case fill plug rounded

[Tony Viv]

Hello All,
I hope this is ok to post here, but my TJ runs so great Ive been working on my 98 Tahoe.
GM did some crazy stuff by putting an alluminum 1/4 drive fill plug in the tcase, and now im in a bad spot. It has completely rounded out. Before it finally rounded I tried heat, pb blaster. No luck.
Any Ideas??? Help please
Also makes me think, after 77k and dozens of dealer oil changes, has no on ever checked the levels of tcase fluid??? One as early as 2 wks ago. I always thought that was standard in oil change service.
Please no flames on the Tahoe or dealer, it was just cheaper at the dealer to get a mobile 1 oil change than it was to do it myself. Guess this is what I get.
just in need of good advise on getting that damn plug out.

[sundevil98]

Could you possibly Dremel a slot in the plug and use a Jumbo screwdriver to get it out?

Other option could be to drill the plug out. Just be sure you have a spare plug to put in there of course. Although, I'd leave that option for last as you may get chips in the case when the bit breaks through.

[Rioshilo]

Your best bet will be to use an extractor. Like a bolt extractor but larger, with reverse spiral fluting and a bolt head on it. I've got an extractor set if you can't find anyone else. I'm out in Surprise.

Rio

[OlneyJeeps]

small pipe wrench should grab what is left (they're great.. the harder you turn, the tighter they grab; a good one can grab as little as a 1/16 rounded screwhead)

Snap on has short (dont want to drill into the tcase) screw extractors that work great too