Crack in 241c Transfercase

[pomai]

Found this crack in the transfercase. Pictures are of before and after I added oil.
What do you think could have caused the crack?
Is that a week spot in the case?

Thank you,
Ed

 

[rampage]

Why are you putting crack in your transfer case, that stuff is expensive! It’s not like it’s going to make it go faster.

 

[6872xtc]

I would bet that there was a driveshaft problem that caused the damage. I saw a 208 split the front output off because the driveshaft mounting flange bolts came out one by one. There was still just one holding it to the flange when I bought the truck.
Usually the transmission tail housing breaks if the driveshaft gets punched backwards, but that could also be the issue here.

 

[obijuank5]

Do you know the history of it? Seems like its from the front output being pushed back. Sometimes in a small collision or the driveshaft being too long on suspension compression.
I had a car pull put in front of me in a right front monster truckin accident that sheared the center pin and did just this.

 

[pomai]

No, I don't know the history, I received it like this, the shop mist it when they rebuilt it.

I discovered the crack while attaching the transfercase shift linkage.

Looking for the front case half know.

Thank you,
Ed

 

[sweetk30]

hope there not the same shop to do your trans that had the wrong part . . . hope you tell us so we can avoid them with these goof ups .

if you cant find one easy just clean the case half of oil and have a good TIG welder fix it via grind out the crack and TIG weld it shut . i use to buy atv's with cases chewed open from sloppy chains and have them fixed this exact way and there still going as far as i know .

 

[pomai]

hope there not the same shop to do your trans that had the wrong part . . . hope you tell us so we can avoid them with these goof ups .

if you cant find one easy just clean the case half of oil and have a good TIG welder fix it via grind out the crack and TIG weld it shut . i use to buy atv's with cases chewed open from sloppy chains and have them fixed this exact way and there still going as far as i know .

Thank you, I wondered if that crack could be welded up

 

[sweetk30]

if you have a good welder with a TIG i see no problem .

reason i say tig is this is better than a spool gun mig style with aluminum wire as there is a lot of thickness here and you need to be able to push the amps threw it for the heat required . and since aluminum dissipates heat faster it requires more amps / heat to keep the puddle flowing good .

i have seen a few spool gun mig welded trans bell housings and they dont last long before they crack again in the same spot . 1 was so bad i didnt last 24hr's . they told me to pull it and they would have the guy redo it . i pulled it before lunch and took it with me on llunch to a friend and he fixed it and did it up for 50.00 bucks . they said wow that was fast and a lot less than the last guy . and i said yep and this wont break here again .

 

[HankScorpio]

Welding the crack is worth a try but don't count on it. Cast aluminum is very difficult to TIG. It actually has more to do with the casting quality than the welders ability. You are basically boiling the impurities out of the casting while trying to weld it up. Mold release agents, oils, sand and other nasty stuff all ends up in the casting. I did a cracked snowmobile engine case last winter and it sucked big time. Had to weld, grind it all back out, weld again, etc. If the casting is clean, not on the surface but IN the metal it will weld ok. You really can't tell until you start the weld. Its already broken so you don't have much to lose.

 

[HankScorpio]

Video of a casting weld. This guy is pretty good and I have picked up a lot of tips from his channel. Hope your casting is cleaner.

 

[Gibby56]

I have nothing to add but I do have to say that is one of the cleanest transfer cases I have seen outside of the ORD advertisements for their magnum case. Sorry to see it cracked.

I’ve had great luck with JB weld in a pinch but your best bet is probably a replacement.