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  • Transfer case leak

    I have noticed recently that there is a slight leak from the fill hole cap and weep hole cap on my '07 Road Star. When I changed the oil, I did not replace the copper washer on the weep hole plug nor the o-ring on the fill plug, as both appeared to be in good condition. Now, with the leaks, I'm wondering if I need to pull the transfer case cover and inspect the chain, or, drain and refill the transfer case and replace the o-ring and copper washer. Comments?

  • #2
    Why drain the oil? Just replace the o-ring and washer. I'd try cleaning out the threads in the hole and the bolts before I replaced any washers.

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    • #3
      One or 2 of Mine are doing that too must need an o-ring a little bit of leak in the transfer case/primary chain housing low torque threaded cover .

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      • #4
        Remove and can just reverse little washer... Hammer it flat... Use heat to aneal it... Or buy a pack of small copper washers. But yeah... Get a toothbrush and brake cleaner and clean real good and put back on bike and plugs... I can't imagine that rubber seal would need replaced unless it got pinched when installing some time
        LET'S RIDE

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        • #5
          is it over filled or the wrong oil and it is foaming and overflowing? If you only filled it to the small oil level hole the oil should never be to the level of the large fill hole. The transfer case capacity is only 13.5 oz, if you put more than that in it then it is overfilled. That is less than a 1/2 qt of SAE80 GL4 gear oil.

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          • Duke
            Duke commented
            Editing a comment
            Another way to check that oil level is to just look at the chain and sprocket thru the fill hole. The oil should be covering the chain at the sprocket when the bike is level.

        • #6
          The oil was changed some time ago. This oil leak is something recent.

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          • #7
            Mine was leaking at the fill hole. Replaced the o-ring and has been good ever since!

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