Dana 60 fill plug question

[KillerBee]

My newly installed Dana 60 has a chrome cover on it, (no  idea what brand)

I noticed tonight it appears there is diff fluid coming out of the bottom of the fill plug.

The plug appears to be just a shiny pipe plug with hex head like in the picture below.

I did a couple wraps of Teflon tape when I installed the plug, maybe I need more?

So when tightening the fill plug how far is it supposed to thread in?

The plug doesn't seem to get totally tight and it seems it would thread completely through and fall inside the cover if you continued to turn it....

Am I missing something?

 Thanks for any suggestions or advice.

[Chryco Psycho]

True pipe thread is tapered & should tighten as a cone would , the cover may be poorly made or tapped too deep for the plug to tighten up properly

[KillerBee]

True pipe thread is tapered & should tighten as a cone would , the cover may be poorly made or tapped too deep for the plug to tighten up properly

I have a feeling the cover is poorly made.

I tested the fill plug on a stock Dana 60 cover I had and it tightened correctly.

I wonder if I could replace the plug with a bolt with nylon washer?

[brads70]

If you go with a new one..... I have this one on mine and am happy with it.
http://www.summitracing.com/int/parts/ktl-304m60

[KillerBee]

If you go with a new one..... I have this one on mine and am happy with it.
http://www.summitracing.com/int/parts/ktl-304m60

Thanks.

I really hate to remove the current one on there but if I have to, Summit Racing is 20 minutes from me.

They sell a few different brands of chrome, stainless and aluminum covers.

I might go up there and inspect a few of them in person.

[Katfish]

I had same problem and Teflon tape cured it.  I'd wrap some more on before replacing it.
If you do get another, make sure you hit the mounting side with a grinder to rough it up.  Had sealing problems with mine before someone informed me the chrome is too smooth and doesn't like to seal.
Had that stupid thing on/ off 3 times before I got it.

[KillerBee]

I've wrapped the fill plug twice now and swapped it out with the plug from a stock Dana 60 cover with the same results.

I'm concerned that when I thread the plug in it doesn't get tight.

It remains finger tight almost the whole way in, by the time it gets fairly tight(never super tight) the plug appears to be too far in the hole and the fluid leaks past the threads.
 
If I leave the plug with the threads half way in and loose I'm afraid the plug will work it's way back out and fall out. 

For those of you with chrome Dana rear end covers how far is your plug threaded in before it gets tight and does it get real tight?

The only fix I can see using this cover is to replace the current plug with a short bolt that I can thread all the way in tight against the outside of the cover with a nylon washer.

[Katfish]

Mine is flush, I have the Summit cover with recessed plug.
Load up the tape and try it again.

[dutch]

make sure the tape is on in the right direction.