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#4807314 - 07/07/18 01:49 AM Why is my transfer case fill plug leaking? Picture
Chris B. Offline


Registered: 03/16/03
Posts: 3476
Loc: Colorado
I have a 1997 GMC Sierra 1500 and keep my transfer case filled up to the bottom of the fill hole to the point it will leak out when you unscrew the fill plug. I have done it this way since it was new. I just flushed the fluid and filled it back up with fresh ATF and now the fluid is seeping out the fill plug. It leaks just enough that a new drop will form in a few days. The plug is tight and I dont know how it is leaking/seeping??? It has never done this before. Any ideas? Would plumbers tape stop it from leaking out? Here is a picture of how much seeps out in a day and eventually it will start running down and dripping.

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#4807315 - 07/07/18 02:04 AM Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.]
SavagePatch Offline


Registered: 05/06/15
Posts: 589
Loc: California
Get the red goop.

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#4807319 - 07/07/18 02:50 AM Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.]
turtlevette Offline


Registered: 12/24/13
Posts: 3649
Loc: Massachusetts
You could swap the fill and drain plugs to see if its the plug or hole. I believe those are tapered threads so the thread clearance reduces as it gets tighter.
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#4807320 - 07/07/18 02:52 AM Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.]
ozdrrider Offline


Registered: 08/10/17
Posts: 34
Loc: South Oz, Australia
Low strength Loctite/sealer. It might be a tapered thread, but it will still leak without sealer.
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#4807324 - 07/07/18 03:48 AM Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.]
dlundblad Offline


Registered: 09/30/13
Posts: 10174
Loc: Indiana
Transmission output shaft seal leak and causing it to overfill?


Edited by dlundblad (07/07/18 03:54 AM)
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#4807330 - 07/07/18 04:21 AM Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.]
demarpaint Offline


Registered: 07/03/05
Posts: 29976
Loc: NY
Wrap some yellow Teflon tape around it. The yellow tape is a bit thicker than the white, its used for gas pipes and works great.
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#4807339 - 07/07/18 05:11 AM Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.]
Lubener Offline


Registered: 01/22/11
Posts: 2604
Loc: N.Ohio
Ignore it. Doesn't appear to be enough to worry about. Probably was over torqued. Usually 2-3 threads should be showing when properly fitted and torqued.


Edited by Lubener (07/07/18 05:12 AM)
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#4807340 - 07/07/18 05:24 AM Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.]
mx5miata Offline


Registered: 03/28/10
Posts: 547
Loc: NY
May have have cross threaded or there was debris that got in the threads. Unfortunately you have a leak there get a thread sealant with PTFE.
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#4807351 - 07/07/18 06:11 AM Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.]
danez_yoda Offline


Registered: 07/18/09
Posts: 494
Loc: texas
Lots of good suggestions here. If it is not dripping a few drops overnight I would flush with brake cleaner, dry thoughtlessly then apply a ring of RTV or make-a-gasket / Make-a-seal (goop) around the outside of the threads. Don't get it in the square hole, just a ring around the threads to seal the weep path.

Next time you service the fluid, put some thread sealer on the threads before reinstalling the screw.


Also check to see that the oil is not coming from somewhere above the screw port and running down the body and only collecting there. The threads may be sealing fine but it is the lowest point on the part so any leaks above it will collect there.

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#4807369 - 07/07/18 06:49 AM Re: Why is my transfer case fill plug leaking? Picture [Re: demarpaint]
billt460 Online   content


Registered: 03/30/15
Posts: 4540
Loc: Glendale, Arizona
Originally Posted By: demarpaint
Wrap some yellow Teflon tape around it. The yellow tape is a bit thicker than the white, its used for gas pipes and works great.


This ^^^^^^^^^^^^^^^^^

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#4807376 - 07/07/18 07:00 AM Re: Why is my transfer case fill plug leaking? Picture [Re: demarpaint]
Trav Offline


Registered: 11/20/06
Posts: 19284
Loc: MA, Mittelfranken.de
Originally Posted By: demarpaint
Wrap some yellow Teflon tape around it. The yellow tape is a bit thicker than the white, its used for gas pipes and works great.


^^^^ This. Its hard to goop oily threads, tighten firmly but don't over tighten tapered threads you can split the case, the tapers acts as a wedge.
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#4807380 - 07/07/18 07:04 AM Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.]
Zaedock Offline


Registered: 09/10/05
Posts: 3948
Loc: Massachusetts
I use white Teflon on mine. White or yellow, it will stop seeping.
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#4807400 - 07/07/18 07:41 AM Re: Why is my transfer case fill plug leaking? Picture [Re: Zaedock]
krismoriah72 Offline


Registered: 02/16/09
Posts: 1577
Loc: wv
Call me Mr. Obvious..but is that O-Ring 20 years old?

https://www.napaonline.com/en/p/NDP7041346

$6 for plug and o-ring.

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#4807462 - 07/07/18 09:00 AM Re: Why is my transfer case fill plug leaking? Picture [Re: krismoriah72]
Trav Offline


Registered: 11/20/06
Posts: 19284
Loc: MA, Mittelfranken.de
Ok Mr Obvious, wrong plug and there is no O ring. .
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#4807518 - 07/07/18 09:57 AM Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.]
Rand Offline


Registered: 08/20/03
Posts: 12721
Loc: NE,Ohio
teflon tape it..

Goop is too messy

just take out the plug inspect threads clean it (brake clean or whatever)

let dry tape it the correct direction for the threads and it will be fine.
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