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Author Topic: Primary Cover Drain Plug Leak  (Read 4476 times)

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ltank

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Primary Cover Drain Plug Leak
« on: June 13, 2016, 07:05:18 AM »
The Torx NPT plug in the outer primary screws in and snuggled up but leaks. It actually feels like it keep going in farther with a little more effort. I tried Teflon tape to no avail.
  Is there such a thing as a slightly over sized NPT plug.  I don't want to go get it tapped out to the next size up due to the Boss area around it is too small to have any strength.  This plug and hole is on the side of cover not in the bottom. I really hate to buy another cover for this problem. Thanks
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ltank

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Re: Primary Cover Drain Plug Leak
« Reply #1 on: June 13, 2016, 08:11:20 AM »
Close up. Torx plug in middle between the two socket head bolts.
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Stevepow

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Re: Primary Cover Drain Plug Leak
« Reply #2 on: June 13, 2016, 12:50:39 PM »
I tightened the plug on my 98 wide glide all the way through into the primary. The plug is tapered and I guess it shrunk. After taking the primary cover off to fish the plug out I replaced with a new plug and that fixed the problem.
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Twolanerider

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Re: Primary Cover Drain Plug Leak
« Reply #3 on: June 13, 2016, 01:00:40 PM »
Quote from: Stevepow on June 13, 2016, 12:50:39 PM
I tightened the plug on my 98 wide glide all the way through into the primary. The plug is tapered and I guess it shrunk. After taking the primary cover off to fish the plug out I replaced with a new plug and that fixed the problem.

You might have some threads worn just enough that Stevpow's suggestion could get you going.  It'd certainly be a cheap and easy option to try.  One other at least potential idea I can think of is to check the catalogs for Colony Hardware.  They have (or at least used to offer) an oversized drain plug for the oil and transmission pans.  If they offered that plug they might offer an oversize plug for the primary also.
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ltank

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Re: Primary Cover Drain Plug Leak
« Reply #4 on: June 20, 2016, 07:33:08 AM »
The Colony 7502-2 is too big to fit. It taps out to a 1/2" x 13 hole.
It will not work. I am waiting for a response from several vendors for a O-Ringed plug. Guess I will drill out the 1/8" NPT then Tapp it to the corresponding plug.
http://www.drainplugmagnets.com/harleydavidson.php
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muddypaws

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Re: Primary Cover Drain Plug Leak
« Reply #5 on: June 20, 2016, 08:01:20 AM »
Teflon tape...
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Bill

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Re: Primary Cover Drain Plug Leak
« Reply #6 on: June 20, 2016, 10:44:32 PM »
Something that might be worth trying before you go to tapping new holes would be a Loctite product 545. It is a sealer for hydraulic fitting and works very well on pipe fittings. I used it regularly on pipe fittings at work and it sems to do a good job and is serviceable without heat
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ltank

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Re: Primary Cover Drain Plug Leak
« Reply #7 on: June 21, 2016, 10:38:52 PM »
Has anyone used the Time-Sert repair kit that you use a 1/2"- 20 drain plug?
http://www.denlorstools.com/autoblog/2013/11/harley-davidson-stripped-drain-plug-hole-best-fix/

Thanks
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Twolanerider

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Re: Primary Cover Drain Plug Leak
« Reply #8 on: June 21, 2016, 11:03:38 PM »
In the 2002-2003-2004 time frame the primary drain plug changed from 1/8 npt to 3/8x24.  If you're still working on something with the 1/8 pipe plug there is no way you've got enough meat to go to anything 1/2 pipe.  Huge difference.
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ltank

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Re: Primary Cover Drain Plug Leak
« Reply #9 on: June 22, 2016, 07:22:57 AM »
Ok .I also see that Time-Sert makes kits that range from 3mm up.
I will take my cover off and make careful measurements then call Time-Sert for the size closest to the 1/8 " NPT drilled out size and find a quality straight threaded oil drain plug from one of the venders. I hope I don't ruin my cover but I will try to repair it to keep my wife from nagging me to death over the cost of a new cover.
She always wants me to ×=%/" rig things instead of a proper fix.
Thanks.  I will post pics after its fixed. It will take a few days to get my parts once ordered online.
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Twolanerider

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Re: Primary Cover Drain Plug Leak
« Reply #10 on: June 22, 2016, 11:42:32 AM »
Quote from: ltank on June 22, 2016, 07:22:57 AM
Ok .I also see that Time-Sert makes kits that range from 3mm up.
I will take my cover off and make careful measurements then call Time-Sert for the size closest to the 1/8 " NPT drilled out size and find a quality straight threaded oil drain plug from one of the venders. I hope I don't ruin my cover but I will try to repair it to keep my wife from nagging me to death over the cost of a new cover.
She always wants me to ×=%/" rig things instead of a proper fix.
Thanks.  I will post pics after its fixed. It will take a few days to get my parts once ordered online.

Some of the Time-Sert kits are expensive.  Have a couple here that were a hundred bucks or slightly over.  Might want to do a little financial common core algebra and figure the cost of the kit while adding in your comfort the repair will actually work as hoped versus just buying another outer primary cover.  Just looked and saw a couple on eBay in the $130-150 range.
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ltank

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Re: Primary Cover Drain Plug Leak
« Reply #11 on: June 23, 2016, 09:14:56 PM »
I ordered Time-Sert 10mm 1.5  thread and a Dimple 10mm oil plug.
I thought I would do this. If I bought a used cover, I thought that it might have stripped plug. My Luck. New covers are expensive. Thanks for all the input guys.
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