Did I just kill my transfer case?

[Ricky_Bobby]

Changed the transfer case fluid last week at 186K miles. I decided it would be a good time to begin changing all of the drivetrain fluids (trans case, front and rear diffs, tranny). I crawled underneath today to check for leaks before starting on the rear diff and saw a small amount of fluid near the drain plug. Cleaned the area with then made sure the drain plug was tight and noticed a small crack.

Is there anything I can do to seal the crack or fix this?

https://photos.google.com/photo/AF1QipPYa4fGxPYFY_MwQFljvql3k0cjBrffVvSa1zqk
https://photos.google.com/photo/AF1QipMoUoqpL9rmUsaECIN5J2xsjcMPelqHhGg21vl7

Thanks in advance for the help/thoughts. I hope this is not the end of the road for the 05 explorer.

 

[mbrando1994]

Is the crack on the drain plug or the case of the xfer case itself?

 

[Mbrooks420]

I'm betting it can be repaired. For any type of sealant to be used it'll have to be CLEAN. The links don't work. Could possibly be welded. ATV/bike cases and cylinders get cracks/breaks welded all the time.

 

[Joe in NY]

You have to use a sealant and make the plug just barely snug. It's a NPT plug. Meaning it gets bigger the more you drive it in. You're cracking open the transfer case. Back it out and put some sealant on it and just barely put it back in. These are cast magnesium casings. Not strong.

 

[Mbrooks420]

Oh, I was under the impression they were aluminum. My bad.

 

[Ricky_Bobby]

This is giving me hope. Can i take out the fill plug, apply some RTV to the threads then switch that into the drain plug? I am only asking to make it a little easier instead of having most of the fluid leak out and make a larger mess. If the plugs are not interchangeable, I can just drain it again. Also, does RTV work as a sealant for this or should I pick up something different?

The crack is hairline starting at the drain plug threads and wraps down around the case about 1.5in long.

How do I upload photos on here, or what website do i need to use to provide the links?

Thanks again!

 

[Mbrooks420]

Imgur to host? Then post link?

 

[Ricky_Bobby]

http://imgur.com/OdNUvaS

http://imgur.com/GsVRh4a

I just backed out the plug a few turns and the leak is much slower. Still leaking a little though. Any suggestions?

 

[p71]

I was in the same boat a few years ago, drained the fluid completely, cleaned the area around the plug with brake cleaner and sealed it up with RTV on the plug and outside the case. It looks ugly but has been holding for six years now with no leaks. I just hope I never have to open it up again, or I'll just siphon out through the fill plug in the future.

 

[Ricky_Bobby]

I am not worried about how it looks, especially on the underside. I just got the leak to slow up this morning but need to drive it about 180 miles to Virginia tonight for work for the week. I am going to top off the fluid and bring an extra bottle and siphon pump then maybe top it off before I drive back on Friday. I will drain it, clean and dry the area then try sealing it all up with RTV next weekend.

Any additional prep work to get the RTV to stick to the case like sanding or will it just stick to clean metal?

Thanks.

 

[p71]

RTV will stick to clean metal. It just takes patience to let the case drain out and using rags/paper towels to reach in through the drain hole to get the last drop of oil out to get the area dry long enough to work.

 

[Ricky_Bobby]

Thanks for all the info. I will probably pull the plug out on Friday night to let it drain then soak up any remaining with some rags on Saturday morning before I seal it up for good.

 

[Ricky_Bobby]

Thank you p71, I owe you a few beers. Your suggestion worked and I have not found any leaks since refilling the transfer case Saturday afternoon.

To note what I did, drained the transfer case over night. All dripping stopped by the morning and I swabbed any fluid out of the case with a shop towel. Cleaned the area with break cleaner and allowed it to dry. I applied RTV to the threads of the drain plug, tightened to just snug, then applied RTV over the crack and surround area. After allowing time to dry, I gave it 8 hours, I refilled the case. No leaks since.

 

[TechGuru]

JBWeld.