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I had a the same prob, the filler neck had a defect around the overflow inlet. It was a raised area that did not allow the gasket on the bottom of the cap to seal completely against the surface on the inside of the filler neck
Slide type caliper I bought at autozone.
AutoZone.com | Vernier Caliper | 6 in. Dial Caliper
Like this one but half the price, it's in the tool section.
If you have a flat surface, this works REALLY well, fully adjustable... did the whole install under the truck by myself. Harbor Freight. Take the brackets I made to hold up the transfercase off, and it works for the tranny also.
I HAVE PREVAILED!!!!!!!!!!!!!
My Fraking rear main seal leak is fixed!!!!!!
I peened down the "dimple" associated with the drainback hole, reassembled the rear main seal housing and seal, put the tranny back in, and, VIOLA!!! no leak... :twisted:
for now..... :-P