Trans/Transfer Oil Return Kit

[Guster]

Hello,

I recently purchased the transmission/transfer case oil return kit from SOR. The kit came with two aluminum type washers. The transfer case fill plug part would not tighten properly unless I used both washers. With a single washer it would tighten to a certain point then just "spin". It doesn't seem like I should have to put two washers there so I'm not sure what's wrong. Everything seemed okay for a few days but now it's leaking. What did I or what am I doing wrong on something that should be so simple to install?

Thanks,
Kevin

 

[forestdan7]

The spinning part makes me a little nervous that your threads are stripped in the fill hole.

Take it out and feel in the hole for metal shavings, and look at the fitting threads to see if there are any on there.

I had a fill plug strip on the transfer case 2000 miles from home in Idaho. I checked the level, and as I was tightening the plug, I felt that sickening loose spinning. Took it out, and luckily it was the plug threads that stripped instead of the case threads. I had an extra fill plug, and it went in and tightened up nice.

BTW, I think the torque spec on the fill plugs is around 36 ft-lbs, which is not extremely tight.

If the transfer case threads are stripped, you might be able to fix it with a tap.

Good luck.