leaky transfer case drain plug

[tomtoc]

changed my transfer case fluid the other day. i've got a coulpe drips of oil under my truck and it doesn't appear to be stopping any time soon. it looks like it's coming right out of the drain plug.

i put a little bit of plumbers tape around the end of it and screwed it back in pretty tight. it's about as tight as i can get it, but just by looking at it, it seems like much tighter and it'll be in too far. (its already indented more than the outside of the t-case).

should i keep screwing? re-tape? something else?
i'd rather not pull the drain plug - filling it back up took forever with a little funnel and hose.

 

[Skandocious]

Can you back the plug out just enough to get some more teflon tape on there and screw it back in? Normally it will not start gushing fluid until you unscrew the very LAST thread on the plug, though it'll drip a little bit.

 

[tomtoc]

fixed...sort of

got it backed out enough to properly seal without losing all the fluid again. but...

after a little cleaning up, i discovered this crack

it doesn't appear to be leaking yet. it's hard to tell b/c it was pretty slow, but i think its fixed.

is the crack weldable? fixable?

 

[tomtoc]

o, and for reference if anyone find this thread by searching about transfer cases and fluid, this is the fluid i used

and you can clearly see the drain/fill plugs on the back of the transfer case here

take the top (fill) out first and then the bottom (drain) plug. plug it back up and fill (mine took about 2 quarts)
...its hard to measure when your wife pours half of it out of the funnel and on your leg

 

[eco]

i put a little bit of plumbers tape around the end of it and screwed it back in pretty tight. it's about as tight as i can get it, but just by looking at it, it seems like much tighter and it'll be in too far. (its already indented more than the outside of the t-case).

That tape probably caused the crack.

I noticed that my service manuals all say NOT to use tape in all the various plugs and fittings that thread into aluminum because the stress from the tape "expanding" the threaded hole that the said fitting threads into will crack.

 

[tomtoc]

Well crap - I knew I needed to buy some actual thread sealer, guess I shouldn't have put it off. So...think that's fixable, or am I going to end up needing a new back half of the t-case?

 

[eco]

From what I understand welding may "work", but the downside to welding something like this is that the heat could (and probably will) warp the casting, plus the heat induced by welding will cost you the heat treating in the casting - meaning that it will be weaker and more succeptable to cracking in the future.

I would look for a replcement at a junk yard if thats an option.

 

[tomtoc]

k, thanks - think its fine to take on a road trip this weekend without worry?

I just don't want to lose all the fluid out on the highway

 

[eco]

How badly do you want to go on the trip? How badly do you want to take the chance?

It's not possible to be able to predict how much will leak or wether or not the crack will spread, you could possibly come up with a thicker oil that will leak less.

 

[Skandocious]

Aren't these transfer cases made out of magnesium?

 

[Skandocious]

Tom -- for the trip -- I'd just throw some JB Weld on that crack (dont get any on the threaded portion or you'll never get the drain plug out) and call it good. Then carry some spare JB weld with you in the truck and you should be fine.