Crack on transfer case

I posted a thread a few weeks ago on how I stripped the fill plug hole threads on my transfer case. I decided to tap the hole into the next size up with a tap. Yesterday I finally got the tap and after I cleaned the area I noticed this crack. I haven't tapped it yet because i'm worried about making the crack worse. Any ideas on what to do next? I was thinking of maybe tapping it anyway and using JB weld on the crack in the hopes that it'll seal. I'd prefer not to have to buy a new transfer case

 

Besides Tig welding it up. Not much you can do about besides JB welding it. You can find a used t case on eBay for about $250

 

Doesn't look that bad, at least not to where I'd consider replacing it. Be extra careful not to over torque the plug when you tighten it, that's probably how it cracked in the first place

 

I'm almost positive thats how it happened. I haven't tapped the new threads in yet, do you guys think thats going to make that crack worsen?

 

JB weld that shit, tap it and jam a new plug in it.
I used JB weld on a cracked VW engine block behind the #3 cylinder on a 2276cc motor, used several tubes of that crap.

Engine never leaked, well it never leaked a drop until I spit a rod out the block at about 8K RPM over a year later. Good luck with your truck.

 

threads look pretty mashed....try running the current correct size tap in there first, see if it cleans up enough to just put a replacement plug in. its just the fill hole, so its not really submerged in oil...then if it tightens up ok, jb the crack with like a que tip or toothpick.

 

That looks bad. Threads stripped and the case cracked. The oil fill is up to that level, so it's not like it doesn't see it.
But not much more you can do than a hail Mary. Plan on a replacement case if you don't get a miracle. Good luck

 

Lmao holy shit. Insane visual of a VW flat 4 shitting a rod hahaha

 

Okayyyyy lol!

OP, you don’t need a new case for this!!! Too many people here are just clueless and just throw money at the slightest problem because they can’t or don’t want to think. Absolute worst case, take it to a machinist who can install a helicoil and tig weld that little crack. If I were you I’d try to tap the hole with the factory size first, and only go larger if that doesn’t make the threads seal. JB weld on the crack.

 

How much for it to be welded and machined vs a good used one? No one wants to weld aluminum that has oil in the crack.

 

I would JB weld and keep my eyes out for a used tcase.

 

If you tap the hole. Be sure to put grease on the tap, that will trap the metal shavings. Don't want that in the X-fer case.

 

This is the route I would take because that crack has extended past the bolt area down to the textured surface.

 

I would tap it larger, clean and JB Weld the crack, Teflon tape the hell out of the new plug and just install snug. The Teflon tape will help hold it in place without much torque and even if it drips on occasion, it shouldn't be enough to hurt anything.