Cracked Transfercase

[Thub]

well i have a problem, went to move the truck this morning and noticed a small red spot on driveway, quick look showed the t case drain plug to be leaking so i figured it needed to be snugged up, well closer examination shows a small hairline crack just below the drain plug, and the plug was by no means to tight, i was easily able to turn it with a 3/8 ratchet.

I had changed the fluid several months ago and it was fine till now, could it be possible that the t case got that hot and the cold snow/slush caused it to crack.

Well i guess my main question is what am i looking at for cost, i am planning on just calling some local junk yards for a used one, but is it possible to just replace the cover or will that involve to much work. this is a bit beyond my comfort range for doing it myself.

 

[IZwack]

It's significantly easier to just swap out the transfer case - which will probably take you 1 to 2 hours if you've never done it before. If you've done it before, then it'll probably take 30 mins.

 

[imp]

well i have a problem, went to move the truck this morning and noticed a small red spot on driveway, quick look showed the t case drain plug to be leaking so i figured it needed to be snugged up, well closer examination shows a small hairline crack just below the drain plug, and the plug was by no means to tight, i was easily able to turn it with a 3/8 ratchet.

I had changed the fluid several months ago and it was fine till now, could it be possible that the t case got that hot and the cold snow/slush caused it to crack.

Well i guess my main question is what am i looking at for cost, i am planning on just calling some local junk yards for a used one, but is it possible to just replace the cover or will that involve to much work. this is a bit beyond my comfort range for doing it myself.

Did it crack in the threads when you tightened the plug after changing the fluid, maybe? Pipe plugs are tapered, and can easily wedge tight enough into threaded holes to cause cracking.

I would drain the transfer case with the front end of the vehicle lifted in the air, so as to get all the oil out, then lower the vehicle, hoping no lingering oil inside will keep contacting the crack. Clean around the crack very thoroughly using strong solvent containing no oily substances. Acetone is good.

1. If you can see that the crack is BESIDE or BEYOND the threaded boss for the plug, after cleaning carefully, smear room temperature curing silicone rubber over the crack area, rubbing it thoroughly into the crack.

or, 2. If the crack is in the threaded boss, as mentioned above, clean the inside carefully with Q-tips dipped in acetone, apply silicone inside the boss and on the plug's threads also (degrease it, too!), screw the plug in, but not extremely tightly, or the crack will be made deeper or longer.

Leave the stuff cure at least overnight, 24 hours better, fill the T-case, and you just may have saved a lot of money. I have successfully sealed oil pans, valve covers, etc. using silicone. Buy the stuff at any parts store or Wally-World, a small tube of it will suffice. Let us know if you try the "fix". imp

 

[Thub]

well the fluid was changed a few months ago and it didnt leak so i dont know why it cracked now. I am not sure how deep the crack is, but it is maybe an inch long under the plug and then reaching up into the plug base. I am thinking of doing the drain and clean and then using some jb weld and rtv the plug in place to the spec 11 ft-lbs. I suppose anything is worth a shot.

And yes i will agree with you on silicone is quite amazing, i have working with aquariums for several years and its amazing what a little bead of silicone can do.

 

[sfbayjay]

I had the exact same problem with my 2002 XLT Transfer Case.

Mine's fixed, for about $20. Details in post #7 of this thread:

http://www.explorerforum.com/forums/showthread.php?t=323399