'95 F250 4x4 ZF5, BW1356 lever-op t-case, 163,000-ish miles.

There's a slight leak from the drain plug of the transfer case. It wasn't loose; couldn't find a torque spec on it, but the fill plug is 7-17 ft-lb, and the drain shouldn't be much more (it's not a fastener, after all). It did tighten a few degrees, but I sure don't want to push it - hard steel plug into an aluminum case, no want crack-y. I'm wondering if I should drain it and put some teflon tape on the plug threads. Is that appropriate for an application like this?

 

I use Gasoila on stuff like that. Guzzle has it on his site. Rectorseal, the one with teflon, might be another choice. Teflon tape, to me, tends to increase the possibility of a crack occuring.

 

Hey, thanks pj. Dang, I posted this on the 'nation last night; only half the views and NO replies. So I appreciate the reply. Just ordered a tube from guzzle.

Dang, lookit that - guzzle ships on Saturdays! From Colorado, it might just be here by Monday.

 

You really have to work the tube of Gasoila to get it mixed. Takes awhile but its good stuff! Bob ships almost instantly.

 

Gasoila came today. You were right; took some mixing. Fluid was about a quart low , and pretty ooky looking. Fortunately we haven't used the 4x4 much.

 

Cr@p! Looked at it again. Didn't notice before - crack in the case right at the drain plug.

Has anyone had success welding the case?

 

OH noooooooooooooo!

 

Here's a rear half on ebay...

1356 Ford Borg-Warner Transfer Case Rear Half / Cover | eBay