[JacoV]

I recently bought a Pajero IO which leaked a little oil on the transfer case cover. I inspected it myself and though it was the galvanized washer between the filler plug and case. As far as my knowledge stretches this should be a copper washer, as it is more malleable creating a better seal.

After about 300km and 300 fights with the wife about the "small" oil stain on the driveway I decided to service the transfer case and replace the washer with a copper washer. I took it mechanic is Alberton that quickly pointed out that the transfer case was cracked on the filler plug hole.

The mechanic (only works weekends) said we had four options
- Try and "CROOK" it by using pratley steel and try to block the crack and leak. (1 week) (R500)
- Remove the cover and send it away for welding (2 weeks) (R2500)
- Try and source a used cover (2 weeks) (R2000 + ????)
- Source a new transfer case cover (8 weeks) (R2000 for the labour and R5500 for the cover from mitsh)

The mechanic seemed knowledgeable but I wasnt willing to be without transport for so long. So after a failed CROOK attempt by myself and Fielies, I took the car to Bosch in Alrode South.

I've been using this Bosch for almost 2 years and never had any trouble with them. They removed the cover sent it for welding, refitted it and serviced the entire drivetrain (inc seals) for R2300. Which I though was a bargain, and all this was done in less than a day.

The little pajero is now going strong (not leaking any oil) only problem is that it battles to float!!

[4ePajero]

Met geweld kan jy jou vinger in jou oor afbreek! (of waar jy ookal verkies om hom in te druk!)

I would suspect that somebody fitted the wrong washer, which did not seal properly.
The plug was then tightened to the point where the casing cracked.

(Collapseable copper washers should be used only once, solid copper washers can be used more than once, but need to be heated with a flame and left to cool slowly, which softens the copper).

A collapseable copper washer needs very low torque to seal.
Every 'handyman mechanic' should have a torque wrench.

(I was tought that, if you don't have a torque wrench, a plug with a copper washer should never be tightened more than what you can achieve with a ±150mm long ring spanner.)

[SimonB]

(I was tought that, if you don't have a torque wrench, a plug with a copper washer should never be tightened more than what you can achieve with a ±150mm long ring spanner.)

And klapped with a 4 pound hammer Just kidding.

A torque wrench is an essential piece of kit.

I realised my torque wrench was also stolen in my garage burglary, and the claim is now settled... and anyone noticed the price of gedore torque wrenches lately?