Transfer case crack

I did reuse the crush washer the first time. I have a new crush washer and drain plug now and it’s still leaking. That was my first thought was I need a new washer but after I put that on it was still leaking and then I noticed the crack.

 

I've heard that as an argument against reusing crush washers.
A motorcycle mechanic friend told me that he'd seen a lot of cracked aluminum engine cases from the oil drain plug. The crush washer gets deformed into the hole to seal things up good. Next time you use it, that force makes it deform further cracking the case. He said if you insist on reusing it, at least flip it around the second time. (Kind of like turning your underwear inside out to get another day out of them )

 

That's why they have 2 sides.

 

The old aircraft method! I like it.

 

I would say welding is the only way. The oil immersion and high tension force once the bolt is tightened, JB Weld IMO would only slow the leak.

 

We used belzona on the block of our D3, crazy expensive but damn that stuff sets up like steel.

 

Thank you for the link to Belzona on eBay. Looks like the vendor is located in Fresno which isn’t too far from me. I’m ordering it tonight

 

This is where I’m at. I drilled a little on the inner part of the drain hole too where the crack was. It looked like the crack didn’t travel through any of the threads. I tried to drill a hole straight through but the angle is bad so I kinda just dug a trench. Now I’m just waiting on the Belzona, should be at my door on Monday. I have brake cleaner and acetone to clean it when it’s time. Would it be a bad idea to just completely seal the plug with Belzona and when it’s time to change the oil again I could just suck it out through the fill hole??

 

I think after the Belzona it'll be fine to use. If you're worried about it you can buy a rubber seal instead of the aluminum crush washers and those take less pressure to seal.

 

Wow that looks pretty good and clean. I cant imagine you having any further issues after the Belzona

 

Looks like you got a nice channel for more grab. Couple things.

1) From duct tape (I think I used that on the block repair and it didn't just melt) or whatever (plastic milk jug, tin) make a stick on dam to keep the filler from just running down and dripping off, you want to keep as much material up there where it counts. Do this before hand as you're buying quick set up epoxy, When it goes hot and reacts, it's too late to start another part of the project.
2) Looks like your going to 'turn the corner up onto the outer face where the crush seal is going to seat, that's fine and it looked like it needed it. A file should get it back to normal after curing.
3) Are you sure with all the brushing, smearing of metal on the part of the case FARTHEST from the threads, you haven't hid some of the crack, like the end of it? I thought it appeared longer. That's where the drill hole would keep it from spreading further into the case. If you don't wan't to drill another hole, (I'm not sure I would either) make sure to get epoxy pulled out onto the casing as far as you can, as thick as you can. (It won't be much, as it tends to run 'til it gets hot, then you won't move it any more)
4) Use popsicle sticks for mixing and applying, I don't know if I mentioned it yet.......this stuff gets HOT! You won't be touching it with your fingers. Rather, DON"T TOUCH IT WITH FINGERS! If it's on your fingers when it reacts, it's going to burn. Like really, really burn and it's epoxy so you're not wiping it off easily.
5) Remember #4. like fight club.

 

You may think about this. Put another hole and dimple with a 1/8th bit along crack or grind out a channel between the 2 holes. with a dremel.

Do all this and dress the face where the washer goes well, and I guarantee you'll never have a problem here again.

On the other hand my guarantee from 1500 miles away isn't worth much I realize.

However I've used this stuff a LOT. It's bad ass. It's the best. We use it in refineries and they don't scrimp.

Are you going to fire the whole batch? (Only way to KNOW it's mixed perfect) or try to half it?

I've played with it some trying to slow down reaction time yet still get good results......it's tricky. Sometimes it never cured. Too much hardener does the same, contrary to what was expected.

Edit: Normal stuff gives you about 15 minutes. I expect this to be about 5. Directions will be more specific exactly IF you mix the whole batch, you'll KNOW your time limitation

 

This is where the crack stopped

 

Thank you for the advice. I was going to apply with a small acid brush first to reach inside the channel and then build up with a popsicle stick. Also I was going to just mix a small amount of it but I guess I’ll do the whole package