Transfer Case Repair

Hello, new member here. I bought a 2008 Tacoma Off Road recently. Truck has been great. Unfortunately I did not notice before my purchase that someone cracked the drain plug on the transfer case. Is it possible to remove the rear of the case without removing the whole Transfer Case? I really want to avoid that if possible. I'm a Tig welder by trade so fixing the crack is not a issue, under the vehicle it'll be way more of a challenge and I rather have it easier if possible. Thanks!

 

I'm pretty sure it'd be possible but getting it back together would be a huge PITA with the front half still bolted up I would imagine.

 

pull drain plug, clean area with brake clean, apply JB weld to crack on the outside and let dry. Clean up any excess. Put plug back in properly, fill, and call it good.

 

This is what I would do to be honest.. or tig it while its on the truck if you're confident enough.

 

I don't think the case can be split without removing the flange for the front drive shaft. If you are planning on taking the case apart to weld, I think it it would be easier to pull the whole case out.

This video shows the disassembly and reassembly of a tcase from a 3rd gen, so you can get an idea of what's involved in splitting the case.

https://youtu.be/DlOm8_Tt81c

 

Is it leaking?
Doesn’t seem like it.
Leave well enough alone until there’s a problem

it may not even be a through crack

 

Yeah, if it's not leaking, or leaking significantly, I'd clean it and put some type of sealer on it.
You could even put a little RTV on the plug when you re-install which will help fill the crack.

 

Something doesn’t look right.
It almost looks like someone repaired the threaded area with a sleeve. And cracked the housing for the plug.

I’d leave well enough alone before you potentially make things worse.

My plug doesn’t look like that.