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Big oops, need advice...

Discussion in '2nd Gen. Tacomas (2005-2015)' started by Imageoguy, Aug 1, 2025 at 3:51 PM.

  1. Aug 1, 2025 at 3:51 PM
    #1
    Imageoguy

    Imageoguy [OP] Well-Known Member

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    Decided to do a few repairs and maintenance on my taco. Amongst other things like changing tensioner (worst part to change, especially when the bottom AC compressor bolts breaks:annoyed:), I decided to change the oil control valve filter since my Taco was regularly throwing a related code. I did a big oops, I overtorqed (I wasn't even close to torq specs?) and cracked the block. As far as I can see, the crack goes to the end of the thread. I'm presently waiting for the JB weld to cure :fingerscrossed: but well aware that it might not contain the oil. And yes, it was pissing oil when I started my truck. I didn't notice the crack before putting everything back together. If my fix doesn't work, any ideas, suggestions? Oh, and yes, I did clean and sand the area prior to JB weld, that was my second coat which, unfortunately, goes a bit over some contamination.
     
  2. Aug 1, 2025 at 4:29 PM
    #2
    INSAYN

    INSAYN Well-Known Member

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    Is that area cast aluminum, or cast iron?

    You said "block", so I would think cast iron. But your image looks to be cast aluminum.
     
  3. Aug 1, 2025 at 4:37 PM
    #3
    Imageoguy

    Imageoguy [OP] Well-Known Member

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    Sorry, cast aluminum.
     
  4. Aug 1, 2025 at 4:44 PM
    #4
    Jimmyh

    Jimmyh Well-Known Member

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    The filter in in the cast aluminum head, not the block.

    [​IMG]
     
  5. Aug 1, 2025 at 4:50 PM
    #5
    Imageoguy

    Imageoguy [OP] Well-Known Member

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    Just tried it again, leaking like a sieve. Driver's side, under the alternator :(
     
  6. Aug 1, 2025 at 4:52 PM
    #6
    Jakerou

    Jakerou Well-Known Member

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    It might be possible to pull the head and get it welded. Know any good TIG welders?

    JB Weld would only be temporary. No way you’d want to trust that to hold indefinitely if it did work.
     
    GilbertOz likes this.
  7. Aug 1, 2025 at 7:22 PM
    #7
    GilbertOz

    GilbertOz Driver

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    This. It needs a welded repair.

    Cast aluminum CAN be welded by an experienced, competent welder who routinely does aluminum tank, frame, engine block, etc. repairs.
     
  8. Aug 1, 2025 at 8:05 PM
    #8
    Jimmyh

    Jimmyh Well-Known Member

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    Unfortunately aluminum welding is so tricky. One slight overheat and it turns into a puddle of aluminum. :(
     
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  9. Aug 1, 2025 at 8:22 PM
    #9
    4x4junkie

    4x4junkie Well-Known Member

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    I'm not familiar with what goes there, but if it's not under high pressure, maybe liberally coat the threads of the bolt or whatever it is that screws into there with RTV, then thread it in there finger-tight (don't torque it down at all). The RTV should create the seal.
    If there's lots of pressure there, then disregard.
     
  10. Aug 1, 2025 at 9:04 PM
    #10
    Imageoguy

    Imageoguy [OP] Well-Known Member

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    From the way the oil pissed from the side of the bolt, even after the JB weld, I would say there's lots of pressure. Also, as mentioned, the crack goes all the way to the far side of the threads, so I doubt the RTV would seal it, and it probably would not be a permanent solution. Looks like I might be looking at a Gen 4 earlier than I wished. It's my DD and I need it for work. Unfortunately, I don't have time and I feel I lack the skills to tackle this project for now. I'm thinking of having the whole job done including welding as you guys recommend, it does seem like the only permanent solution. I might make myself a birthday present a year earlier than planned. Just wish I didn't make such a costly error. Thanks for the advice!
     
  11. Aug 1, 2025 at 9:40 PM
    #11
    GilbertOz

    GilbertOz Driver

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    Right, of course, hence my qualifier that the welder be "competent and experienced," specifically with welding aluminum. They are out there.. (I'm not one.)
     
    2015WhiteOR and INSAYN like this.
  12. Aug 1, 2025 at 10:29 PM
    #12
    joba27n

    joba27n YotaWerx Authorized tuner

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    I know a guy but he's in Fort Mac Alberta... not me, a former co-worker whos building a 80's vintage 4runner with a tdi under the hood. Even welded a custom intake manifold along with custom coolant pipes... next best would be a welder who deals with boats. They tend to be artists with tig welding which is what you need here
     
    GilbertOz[QUOTED] likes this.
  13. Aug 1, 2025 at 10:55 PM
    #13
    goforbroke123

    goforbroke123 Well-Known Member

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    Find a mobile metal fabricator. You know the guys that drive around in the duallys, with multiple welding machines, and a big old Wilton vise mounted on the bumper. I know you have those dudes in Canada, especially with all the rust up there lol. Start calling around, send them pictures etc….
     
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  14. Aug 2, 2025 at 7:47 AM
    #14
    GilbertOz

    GilbertOz Driver

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  15. Aug 2, 2025 at 8:35 AM
    #15
    3JOH22A

    3JOH22A トヨタ純正男娼

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    Unplanned upgrades are the best upgrades :laugh:
     
  16. Aug 2, 2025 at 11:46 AM
    #16
    INSAYN

    INSAYN Well-Known Member

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    Welding cast aluminum isn't rocket science, but is tricky with oil soak to deal with.

    It might be recommended or even required to actually remove and bench the head so it is easier to properly clean and work on for the TIG guy.
     
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  17. Aug 2, 2025 at 9:18 PM
    #17
    tacokarl

    tacokarl Big Blue

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    Checked the service manual, torque spec is 46 ft-lb. Just out of curiosity how tight did you tighten it?
    oil.jpg
     
  18. Aug 2, 2025 at 9:20 PM
    #18
    b_r_o

    b_r_o Gnar doggy

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    You'll have to pull the head no matter what kind of repair you attempt.

    Probably easier in the long run to just buy a new head
     
  19. Aug 3, 2025 at 5:35 AM
    #19
    JAGCanada

    JAGCanada Well-Known Member

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    I stripped the transmission drain plug tightening it with a torque wrench.... It stripped before getting to the specified torque. Since then, I haven't used a torque wrench on any wet threads.

    I just found this video which is some guy doing a simple test of the tension in a bolt, with dry and wet threads, at a standard torque setting. It isn't the most scientific setup, but a quick and good visual of difference in clamping forces you can expect with dry vs wet threads. https://youtu.be/lwlLbXowM4Q?si=NJ0XKEUDYSaMLLcf

    I suspect the OP was under the torque setting and the threads were wet with oil.
     
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  20. Aug 3, 2025 at 6:56 AM
    #20
    Clearwater Bill

    Clearwater Bill Never answer an anonymous letter

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