I was changing the oil in my transfer case. I pulled the front plug, as I was told by a Dodge technician, or also called the shift lever retention plug. When I put it back in, the casing broke and a piece fell into the oil pan. It is one of the plugs with an O-ring, so I know it is not that tight. I hand tightened it and then put a 3/8" ratchet and tapped the end of it with one finger to snug it. The side facing the front of the truck snapped off and fell into the oil pan. About half of the threads broke inside the transfer case. After looking at it, there was a huge air bubble in the casting. The O-ring is still in good shape, so I am thinking it was not over tightened. The Chrysler dealership service manager told me that I over tightened it and there was no flaw in the casting. I showed him the piece witht he bubble in it and told him to look under the truck. He refused and said I broke it so no warranty.

I guess now my question is how much for a new transfer case? Should it be covered by warranty since it was a casting flaw?

 

I'd run it up the chain @ the dealer, if there is a bubble(casting flaw) it doesn't matter who broke it!

 

Or another dealer or ask to see a Factory Rep ASAP.Service manager should NOT be a *** about it.Thats a NICE BIG EASY ticket(money)as long as approved by D.C. When I wrote service I'd like to see a handful of those come in!! Parts would LOVE it also(40% markup over cost)

 

Like it was said earlier, run it up the chain to DC to resolve, not the dealer.

Next time you drain and refill, you may want to use the drain and fill holes located at the back of the transfer case - real simple. Torque them to 30-40 ft lbs.

 

I found those plugs after I took this one off.

I took it to the dealer I bought it from. They are going to look at it on the 25th. I spoke to the sales manager, he sold me the truck, and he said there should not be a problem to fix it. I am writing a rather long letter to the dealer who refused to help me.

I did find out that the transfer case for the NV5600 is $1100 brand new. I hope it all works out.