Thumb rules:
- Oil/grease if specifically requested (FSM sez, for the crank nose screw, "dip in engine oil and torque to 80 pound-feet," for instance.)
- Thread sealant onall pipe joins (use the "Torque Angle" method, and friction is immaterial,) or if specifically requested (#11 cylinder head screw, for instance.)
- Never-seez gets used anywhere that is likely to stick - I don't use it on threads very often, but I do us it on shanks and shafts, taper studs, and the like (tie rod ends get it on the taper shank, for instance. I also often put it on the shank of the bearing assembly, where it goes into the bore in the knuckle.)
- Never-seez gets used on pressed assemblies - ball joint sleeves, Cardan joint caps, and like that.
- Never-seez is also used to "extend the capability" of tools. For instance, the stub shaft nut on the front axle out gets 185 pound-feet of torque. However, my biggest torque wrench only goes up to 150 pound-feet. Using never-seez reduces friction significantly between mating threads, so that means that the applied torque (turning force) can and should be reduced to achieve the same tensile preload (stretching stress.) Thumb rule is to reduce by half - using never-seez on the stub shaft nut means I only have to torque it to 92-93 pound-feet - which puts it well within the reach of my tools.
(Yes, this is correct. Yes, this works. I've been doing it this way for a number of years, without failures. I shall continue to do so until I hear otherwise from the manufacturer. The "torque reduction" information will be given below. Note that applied torque should be reduced by half if never-seez is used, for whatever reason.)
I referred to "torque angle" with pipe fittings - this means you tighten it to "finger-tight" (fingertip pressure,) and then give it a specific amount of turn ("flats past finger tight" - or "FPFT",) rather than an applied torque. This applies with or without sealant - but is better with. How far?
through 1/4" nominal: 1/6 to 1/4-turn. (1 FPFT)
Above 1/4" through 3/8": 1/4 to 1/3-turn (2FPFT)
Above 3/8" through 1/2": +/- 1/2-turn (3FPFT)
Above 1/2" through 1": 2/3-turn to 1 turn (4-6 FPFT)
Above 1": 1.5-2 turns (9-12FPFT)
Tighten to specified value, monitor through 1-2 days' service for leaks. Tighten in 1-flat (1/6-turn, or 60 degree) increments - torque on flat, re-evaluate.
If you have to nip it up twice or more, replace or recondition the fitting - something's wrong (threads are probably bruised, or the base material has been gouged.)
Torque modification values for applied lubricants (% of given "clean, dry" book value):
100% - LocTite
90% - Thread sealant (PTFE paste or tape, but not LocTite #545 Hydraulic Sealant)
80% - Engine Oil, chassis grease
50% - Anti-seize compound
My thumb rule is that a bolt doesn't go in dry, so that table has been tattooed on the inside of my left eyelid (just in case I need it...)