4x4 transfer case motor repair

[bs1231]

I am a newbie here. I thought to post this in the 4x4 section, but it appears to have a lock.

First, I want to thank everyone for the picts and information on the 4x4 diagnosis/repair. Very helpful to me as I was diagnosing why my i had no 4x4. This forum is an awesome resource.

After testing the relay, I went for the motor/sensor on the transfer case.

The good news: The bushing was in pieces.

I wish I was lucky enough to finish the job as others have, but I have a problem.

The bad news:

I have one torque head that broke off. Going for my easy out, I drilled the screw perfect, then my easy out broke off in the screw. Not an ideal situation for a one hour project

Now I had to get creative. I sliced across the screw and through the pot metal with a hack saw (past the easy out tip) hoping to get a flat head on it and twist. That didn't work either.

So after running to the hardware store, and getting another easy out bit, I managed to drill the hole further down, put my new easyout in there...

Yep you guessed it, that one broke off as well.

So now I have too many hours in this project and a mess on my hands.

In addition to the story line, I used lube, heat and vibration to no avail.

I have two questions:
I assume I am going to the junkyard/craigslist now, to try and locate this unit. Seems a shame to waste my time on this anymore unless someone has another idea for me?

If anyone has an extra one laying around, I am interested. All I need is the housing.

Does anyone out there replace those stupid no tamper torque heads with standard phillips heads?

Thanks!
Brad

 

[DeRocha]

I replaced all the security torq bolts with a regular bolt back in the day (sorry I don't recall the size). Is there some way you could re-assemble the cover with RTV and the 2 remaining cover bolts?

 

[bs1231]

Thanks, I was wondering if I could get away with 2 bolts (i think they're 8x32 standard).
I don't know what rtv is.
I suppose I could try and drill out the old bolt, then attempt to tap in a different thread?

 

[Shadow91]

PM me, i have one for you. =)

 

[DeRocha]

RTV is an adhesive sealant that bonds parts together. As I see it your case is already fubar'd so fixing it in any way to get it working is the way to go. You can certainly try drilling it out and tapping the hole for a larger bolt.

 

[bs1231]

Thanks for the feedback.
It looks like I have room to go deep. So today I am going to try and drill out the bolt, and go down another 1/4-3/8 inch. Tap it with the same size thread into the new material, and put a longer bolt in.
I'll let you know if it works or not!

 

[bs1231]

It worked! I was able to drill down, tap it out, and get it all back together today. And it all works! 4x4 is back!
Thanks again for your help, reading my posts and for all the info on this forum.

If anyone needs to know, the thread is 8x32 standard.

Brad