When I got my oil changed last week they told me my transfer case plug needed to be replaced. The oil change place said it was loose, or wobbly, something like that. I went to a local auto parts store, O'Reillys, they didn't have one in their computer. Which means they can't get me one. The guy at the store suggested, if I could find out the size of the transfer case plug, trying an oil pan plug.

Is there somewhere online I can get one? Where on the transfer case is the plug located? When I replace it, will it dump all of my tranny fluid? And lastly, how many quarts of fluid would I need for a refill? It's due for new tranny fluid, I figure I might as well do that while I'm messing around under there.

 

I am very skeptical about this... was it the Trasnmission or the transfer case? those are two separate things. The transfer case should not have a loose plug, not sure why that would be in the first place.

How many miles you have on the truck? that will tell us a little bit more, and where did you get your oil changed?

 

The transfer case plug is a lot larger than a standard oil pan plug, so you won't be able to fit one that way. I think you should find out whether your problem is with the case or the plug - the case is aluminum and if someone cross-threaded the plug during an oil change, they could have ripped out all the threads giving you a real problem to deal with. Take the plug out and have a close look at both the plug and hole to see where your problem lies.

 

Truck has about 130,000 on it. They said transfer case. Oil was changed at a local place I've been using for over 10 years. I was/am worried they cross threaded it.

 

If you havent had your t-case fluid changed... yeah you probrably are due, try calling a junkyard and seeing if they have any dakotas in stock that they could pluck one from. Or call somewhere Like a AMACO Transmission place, they might be able to tell you where to get a plug.

It does sound like it got stripped... there really is not too many other reasons you need a new plug.

 

probably have to go to the dealer for that plug if you cant find one in a junk yard. There is a parts manual in the sticky section you can find out the part number and call them up for a price.

 

I can't see a problem with the plug being as common as stripped threads in the transfer case itself. If you are not due for a transfer case fluid change yet then just hit the outside of the plug with some RTV for now. When it's time for a fluid change then you can thoroughly inspect the plug and the threads to see where your problem truly lies. If it is the plug, get one from the dealer, it can't cost much. If it's the threads, then you have two choices: remove the cover and re-tap or just do the RTV thing again around the plug till next time...

 

That's a good approach, just remember to clean the plug and transfer case area around the hole with some carb/brake cleaner on a rag (don't spray it into the hole) before you squeeze the RTV on. Once the RTV is on and the plug is in as well as it can, let it set up before driving it around much.

 

What about using some thread locker? If I use RTV on it, would the oil change place be able to check the fluid in it?

I may see if I can find a new plug at a salvage yard. It can't be too expensive for one of those. If that doesn't do the trick, I can go from there.

 

If the plug is loose, thread locker won't work and isn't used as a sealant. If the plug will screw in reasonably, even if it has some wobble, the RTV will give it more than adequate grip after it has set, but it MUST set on clean metal, otherwise it'll just peel off. In my opinion, you should first remove the plug so that you can see how loose it is and where the damage is. Once you do that, the temporary or permanent remedy can be easily applied. You should have plenty of room to do this and you may be able to loosen the plug enough to remove by using a large pair of slip lock pliers or a large adjustable wrench.

When you put the plug back on with the RTV (either the black or red will work there), just make it snug (the RTV should squeeze out somewhat from around the plug head) and leave it for a few hours to set up. After 24 hours, the RTV is fully set, and I'd probably leave it for that length time, but a few hours is needed,