Originally Posted by DeKalb

I was going to wait till Spring to post this but thought it might help someone doing this repair during the Winter. I apologize for not having more testing miles. Due to the weather we have been having my Crossfire is sleeping till Spring. I will update the results along with the accumulated miles once I bring it out of hibernation.

My 2005 Crossfire currently has 101k miles. I got my Crossfire in August of 2021 from a local Chrysler dealer. They attempted to fix a breather oil leak before I took possession. The passenger side they used a lot of RTV and the driver side not enough, so I had a slow leak from day one.

I have corrected the leak on both breather covers and that is what I want to share with you. I first tried grey RTV because I had it on hand, that didn't last long. However, what I found recently may be the answer to the breather leak problem, while using very little RTV.

Fluoroelastomer O-Ring Cord Stock Chemical-Resistant, Soft, Durometer 55A,3/32 Fractional Width, 395 degree temp, 3 ft. Length
The 3/32 size fits in the groove on the covers and holds in place while installing the covers. The soft Durometer of 55A allows the material to be compressed to provide a good seal and allows the full torque spec to be reached. RTV is only needed on the bolt hole lugs and one small area on the passenger cover between two lugs. Each cover took a 3 foot length to install the seal. This type of O-ring cord is excellent against gasoline and synthetic fluids. The 395-degree heat rating is more than enough for the application location. The driver side is one continuous cord, passenger side is two pieces. Both have a Dab of RTV at the joints. Due to the O-ring cord and the RTV being in the same temperature range and both rated for automotive use, I do not expect any conflict with two different materials.

I have installed this on both covers in my Crossfire and have done a test drive of around 60 miles with no leaks. I found the O-ring cord online thru McMaster Carr, I have purchased from them several times over several years and trust their product. My total cost for this was $27 … $7 each cord and $13 shipping. I also changed the five small aluminum bolts to the stainless steel while doing this fix.

This has worked for me and I hope it will work for others. As long as you use equal amount of care and prep as I have, you should have good results as well.