Review on 🏠 Dorman 917-561 Transfer Case Housing: Stylish & Durable Black Casing by Darryl Blumenthal

Same problem as the others, leaking drain and filler plugs. The factory case uses tube plugs (tapered threads). Dorman uses a standard 16 x 1.5mm straight thread. You say to use a non-hardening sealant but I don't see how that would work since the fluid gets on the filler threads and later when you change the fluid you can't remove the fluid from the drain threads. The liquid will render the sealant ineffective. I have used Dorman #090-054 drain plugs with a fiber washer, but they also leak because the body was not machined to fit the washer. Most people don't have a way of doing this, but I put a .100" thick, 1/2" ID o-ring on the drain and fill plugs. I then put a 3/4" x 1-1/4" 14 gauge machine washer (about .075" thick) over the o-ring. But I had to drill the washer to .800" ID to get through the o-ring to come out after it has been pulled over the plug. This allowed the o-ring to shrink about 0.025 inches to create a good seal and the washer keeps the o-ring from extruding. I also had to carefully file the rib on the filler plug to allow the washer to fully seat against the body. The roller clamps on the pump worked very well.