Yep, I could see where someone not used to working on stuff like this could damage the case, which would not be a good thing. Do it yourselfers just remember if it is not going on smooth it's not going on right,If you continue putting it on you have it cross-threaded and are cutting new threads. You have ruined the case. It's easy to put on. Just set the cap on, gently move the cap around, it will find where it needs to be. Gently start turning the cap, it should start threading. You should be able to screw it all the way on with no effort. Just remember all nuts,bolts,screws, and the like should go together easily, if not there is an issue. Check for damaged threads, dirt, grit etc. in the threads. Be especially carefull with aluminum and other metals of this type. People can really mess up putting spark plugs in. Just be carefull.

Wildrat

Post edited by: wildrat, at: 2005/11/18 23:36<br><br>Post edited by: wildrat, at: 2005/11/19 09:02

If you had to change wrench size when you were pulling the drain plugs you have pulled the transfer case drain plug. Both drain plugs for the engine oil are the same size I think a 17mm. I did the same thing when I first got my bike and this sounds to me like what you have done.