Engine/Transmission (1994 - 1998) Transfer Case Dripping Fluid Help

[TDickerson]

A few months back a had my transfer case fluid changed and the guy could not remove the fill plug because it was put in too tight previously by the dealer. He had to drill it out. He replaced the plug, but was scared to tighten it too much. Well it started to leak pretty bad and I took it back. He put some teflon tape around it and it was OK for awhile but started dripping again. I took the plug out and it seems the fluid just eats the tape up. Anyway, what sealant can I use that will stop this leak so I don't have to overtighten the plug and will be easy to remove later. I'm afraid to us locktite as I might not get the plug back out again without striping the inside of the plug again. It seems very easy to round the plug out. I'm not real mechanically inclined but can do simple things like this. I would highly recommend anyone changing xfer case fluid to remove the fill plug before removing the drain plug.

 

[Willys]

What part are you talking of rounding out, inside or out? Inside is torx, outside hex... I always use a big adjustable(crescent) wrench to get it off- never have had a problem with stripping the nut, or overtightening. I think there might be a seal on the nut?

 

[TDickerson]

It's inside. Seems it must be all aluminum and pretty soft.

 

[Willys]

Torx are lame, use a big wrench on the outside, turn it until it stops leaking, but before it strips the threads.



Edit: I think mine is steel.