Cracked Transfer Case

Cracked my transfer case putting the drain plug back in. I used a torque wrench set correctly and it didn't max out for some reason, now I have a hairline crack down the threads.

I drilled a hole at the end of the crack to stop the crack from spreading and cleaned/roughed the surface. I applied Quiksteel (like JB Weld but stronger) around the outside. I also added a new crush washer. There is still a very slow leak of oil as part of the crack goes right down the threads. I can't use teflon thread tape because it will dissolve in oil, is there anything else I could try? My other option is to just use Quicksteel over the entire cap and stuck the oil out of the fill cap with a pump next time it needs to be changed. Truck has 240k miles and the transfer case oil hadn't been changed in probably 100k and still wasn't dirty, so maybe it will go the life of the truck without needing to be changed. Suggestions?

 

Some industrial Teflon tape and paste is fine for oil use. I think you can buy the rear cover separate too?

 

Yep I think you can get oil/diesel teflon tape, but I've never really had a problem using regular teflon tape on stuff with oil in it.
Also if you drain it out and clean it real good I've used seal-all to temporarily stop a diesel tank from leaking. Worked for a few weeks. Got it from oreilly looks like some as seen on TV stuff.

 

Not to revive an old thread, but I have the same crack but way worse, what’d your end solution be?

 

Pictures to judge just how bad.

Over tighten the drain plug ?

A epoxy good for gear oil getting things clean can be interesting .

Find a another Transfer case ??

Can you weld Aluminum??

Paying normal labor to weld a used case would be cheaper

 

I've seen these magic aluminum brazing rods at cars shows, used a propane torch and could weld aluminum cans together. Or maybe use a ton of pipe dope on the plug.

If you dont work on cars much maybe take it by a welding shop and see if they could weld the crack, that probably what I would do first unless they wanted into the hundreds of dollars just to weld a small crack

 

I would stop drill it and try JB weld. Best case scenario it stops the leak, worst case is you are right back where you started. Next time only hand tight on the drain plug!