Repairing Transfer Case Crack

[mudman83]

I recently rebuilt my np241 transfer case and noticed a small leak. It turns out that it has a small crack in the front of the case by the front driveshaft output that I did not notice while rebuilding. Is welding over the crack an effective repair or is the case junk?

Thanks,
Kyle

 

[BKinzey]

Can you weld aluminum? If you do it right yes If you can't, get an estimate from someone who can. That will determine if you think it is worth it or not

 

[mudman83]

I was wondering if the crack would mean the case is ready to fail anyways. I can weld aluminum, I just don't want to do the work if it will just break again. Has anyone sucessfully repaired a crack on a transfercase and not have it comeback?

 

[bigblock72]

I've repaired t-cases and transmission cases as well. The castings are quite porous and dirty and can be difficult to weld. If you get good penetration and burn enough of the contamination out of the base aluminum it'll be a good repair as long as you use a TIG. All bets are off if you try and MIG it though.

Make sure your front driveline isn't too long, bottoming out when the front end is compressed and putting stess on the case itself. I've seen many a case break off from too long a driveshaft and spirited driving.

Also check to make sure nothing is rubbing on the case and putting pressure on it. Cast aluminum is easy to break and/or rub a hole through so make sure everything is where it belongs.

 

[mudman83]

Ok, thanks for the info. I will go ahead give it a try.