Is there a replacement check level plug for the transfercase? One that has a thicker head. The stock plug's head is so thin that I'm starting to round it off.

Good question ~ I do recall someone saying it had to be of some special material because of the case being magnesium alloy. I read in some service manual about a necessary coating for the threads ~ personally I use teflon tape and haven't worn mine out yet but for something like this would get another from the dealer.

Is there a replacement check level plug for the transfercase? One that has a thicker head. The stock plug's head is so thin that I'm starting to round it off.


How often are you checking it?

Every 7500 miles, when I change my fuel filter. Also check fr/rr axles at the same time. On mine I could put the plug in finger tight and then to get it off is bear. If it gets to bad I'll just have to get a new one but it would be nice if someone made a better plug, with a thicker head.

I would also ask why you are checking it so often? Is there a problem you are worried about?
If so look into fitting in a sightglass fitting. One that has a small window on the plug to show the level in the case. I know the level of the filler plug is to be just below the hole, but if you are able to find something like this you could jack up the rear end so that liquid is toward the front of the case and then fill it up just enough to be able to show on the siteglass.

Are you using a 12 point socket or Cresent-Hammer? A 6 point socket will minimize rounding plug.

I think it said in the book to check ft/rr axles and T-case every 7500 when you rotate the tires. I know it doesn't leak because my garage floor is clean but I check it anyway.

Modified, I use a 6 point wrench but because of the angle of the wrench (the angle of the box end in relationship to the shaft of the wrench) and the position you have be in to unscrew the plug is hard to keep the wrench perpendicular(plug head inside of box end of wrench) with the plug. Therefore, with the thin plug head it tens to want to round off the plug. Do you know if a shallow well socket will fit between the T-case and the cross member? If so I'll give a 6pt socket a shot next time.

Are you using anything like liquid teflon or teflon tape on the threads of the plug itself? It almost sounds like a dissimilar corrosion issue, since I can't remember what that plug is made out of, going on between the plug and the case since you mention that it seems to be self tightening.