Jacuzzi SWG leaking

I have a jacuzzi SWG and the housing started leaking at the screw on cap this summer about a month or so into the season. I took it apart and put it back together with pool lube and it progressively got worse. I thought it was a bad o-ring even though the o-ring looked fine. I ordered what said it was an exact replacement from an online pool store. It is not the same, slightly larger diameter, and the leak turned from a steady drip to a stream. I tried to tighten it up and it made it worse. I put the old o-ring back in with pool lube and it started up looking like it improved but within 30 seconds it was leaking again in a steady stream. I don’t see any cracks in the housing or cap. I’m not sure what else to do. Any help is greatly appreciated.
 
Your signature says you have an aquarite - is this an alternative replacement cell?
What model do you have?
 
If you can’t get the leak stopped you may be able to get a new housing- i see some on ebay for about $50.
 
Are you sure you're not starting too tight ? It took me years to realize that my 'hand tight' was more than the much older PB's 'hand tight plus 1/4 turn'. *Years* of fighting drips every spring. Since then i go what I consider 'snug' and tighten just a little if there's any drips until the stop.
 
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Many possibilities imo. Could be threads on the cell are too thin so they don't quite match up with the threads on the union. Try wrapping a couple revolutions of teflon (plumbers) tape on the side that is leaking. You can also try a couple rubber spacers between the cell and the union. Also the particular ABS plastic being used by Jacuzzi, over time, may have a chemical reaction with saltwater and heat which can cause the threads to become brittle and just chip off during normal unscrewing. I'm pretty sure their manufacturer in China is my former supplier. In my case, the mold being used was so old that it got deformed, especially around the ends of the cell so the surface wasn't completely flat when the mated up the two sections of the cell. Check along the seam at the ends and see if your fingernail gets caught on the seam.
 
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