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Why is my transfer case fill plug leaking? Picture #4807314
07/07/18 12:49 AM
07/07/18 12:49 AM
Joined: Mar 2003
Posts: 3,514
Colorado
Chris B. Offline OP
Chris B.  Offline OP
Joined: Mar 2003
Posts: 3,514
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.

Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.] #4807315
07/07/18 01:04 AM
07/07/18 01:04 AM
Joined: May 2015
Posts: 668
California
SavagePatch Offline
SavagePatch  Offline
Joined: May 2015
Posts: 668
California
Get the red goop.

Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.] #4807319
07/07/18 01:50 AM
07/07/18 01:50 AM
Joined: Dec 2013
Posts: 3,756
Massachusetts
turtlevette Offline
turtlevette  Offline
Joined: Dec 2013
Posts: 3,756
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.


USA-1
Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.] #4807320
07/07/18 01:52 AM
07/07/18 01:52 AM
Joined: Aug 2017
Posts: 49
South Oz, Australia
ozdrrider Offline
ozdrrider  Offline
Joined: Aug 2017
Posts: 49
South Oz, Australia
Low strength Loctite/sealer. It might be a tapered thread, but it will still leak without sealer.


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Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.] #4807324
07/07/18 02:48 AM
07/07/18 02:48 AM
Joined: Sep 2013
Posts: 10,674
Indiana
dlundblad Offline
dlundblad  Offline
Joined: Sep 2013
Posts: 10,674
Indiana
Transmission output shaft seal leak and causing it to overfill?

Last edited by dlundblad; 07/07/18 02:54 AM.

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Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.] #4807330
07/07/18 03:21 AM
07/07/18 03:21 AM
Joined: Jul 2005
Posts: 30,952
NY
demarpaint Offline
demarpaint  Offline
Joined: Jul 2005
Posts: 30,952
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.


God Bless Our Troops

Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.] #4807339
07/07/18 04:11 AM
07/07/18 04:11 AM
Joined: Jan 2011
Posts: 2,820
N.Ohio
Lubener Offline
Lubener  Offline
Joined: Jan 2011
Posts: 2,820
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.

Last edited by Lubener; 07/07/18 04:12 AM.

The "thinking" man's friend.
Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.] #4807340
07/07/18 04:24 AM
07/07/18 04:24 AM
Joined: Mar 2010
Posts: 654
NY
mx5miata Offline
mx5miata  Offline
Joined: Mar 2010
Posts: 654
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.


NAPA FULL SYNTHETIC 0w20 Partsplus oil filter
Wix air filter
Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.] #4807351
07/07/18 05:11 AM
07/07/18 05:11 AM
Joined: Jul 2009
Posts: 742
texas
danez_yoda Offline
danez_yoda  Offline
Joined: Jul 2009
Posts: 742
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.

Re: Why is my transfer case fill plug leaking? Picture [Re: demarpaint] #4807369
07/07/18 05:49 AM
07/07/18 05:49 AM
Joined: Mar 2015
Posts: 5,149
Glendale, Arizona
billt460 Offline
billt460  Offline
Joined: Mar 2015
Posts: 5,149
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 ^^^^^^^^^^^^^^^^^

Re: Why is my transfer case fill plug leaking? Picture [Re: demarpaint] #4807376
07/07/18 06:00 AM
07/07/18 06:00 AM
Joined: Nov 2006
Posts: 20,559
MA, Mittelfranken.de
Trav Offline
Trav  Offline
Joined: Nov 2006
Posts: 20,559
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.


ASE L1, Master. Deutsch Meisterbrief.
Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.] #4807380
07/07/18 06:04 AM
07/07/18 06:04 AM
Joined: Sep 2005
Posts: 3,953
Massachusetts
Zaedock Offline
Zaedock  Offline
Joined: Sep 2005
Posts: 3,953
Massachusetts
I use white Teflon on mine. White or yellow, it will stop seeping.


2016 KIA Optima SXL 2.0L Turbo/2012 F150 Ex-cab 5.0L
1992 YJ "The Heep"/2015 Chrysler 200 Limited
1975 Ford Bronco/1959 Willys CJ5/20XX Custom rock crawler
Re: Why is my transfer case fill plug leaking? Picture [Re: Zaedock] #4807400
07/07/18 06:41 AM
07/07/18 06:41 AM
Joined: Feb 2009
Posts: 1,585
wv
krismoriah72 Offline
krismoriah72  Offline
Joined: Feb 2009
Posts: 1,585
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.

Re: Why is my transfer case fill plug leaking? Picture [Re: krismoriah72] #4807462
07/07/18 08:00 AM
07/07/18 08:00 AM
Joined: Nov 2006
Posts: 20,559
MA, Mittelfranken.de
Trav Offline
Trav  Offline
Joined: Nov 2006
Posts: 20,559
MA, Mittelfranken.de
Ok Mr Obvious, wrong plug and there is no O ring. .


ASE L1, Master. Deutsch Meisterbrief.
Re: Why is my transfer case fill plug leaking? Picture [Re: Chris B.] #4807518
07/07/18 08:57 AM
07/07/18 08:57 AM
Joined: Aug 2003
Posts: 13,137
NE,Ohio
Rand Offline
Rand  Offline
Joined: Aug 2003
Posts: 13,137
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.


2019 Jeep Cherokee Trailhawk 2.0T
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