bigaaron

keep in mind very small crack from driving the plug in to far. Crack about a 1/4 to 1/2 inch long

drain t-case ( i would give it a few hours for all dripping fluid to drain)
coat drain plug threads with permatex black and install (keeps dirt out of t-case and any residual drips from getting onto surface)
wipe clean
clean with sandpaper
spray with carb cleaner, let dry
use small dremel with a grind stone to clean area and rough up surface
spray with carb cleaner, let dry
apply JB Weld (let dry for 24 hours- very important)

NOTES:
while the area of the crack was very small, the surface I roughed up was 3" x 3" to give the JB Weld enough surface area to hold and bond.
if the surface is wet with t-case oil it probably will not stick and leak (this happened to me the first time)
I used carb cleaner to remove dirt from sanding / grinding
Also coated the drain plug with permatex black (also needs to dry 24 hours)
if you need to do a clean catch of that expensive t-case synthetic oil buy a aluminum roasting pan from $1 store
the key is surface preparation
Maybe give Marine JB Weld a look

bigaaron

been driving a week so far - no leaks

mbb

Thats not my idea of "fixed"

Jb weld is just epoxy ....with filler.....not magic.

You smeared goop on it.

Id consider that temporary and start cruising the U-Pull-It yards for a transfer case

When you quit routinely checking it, is when it's going to fail and let you down. Or you could get lucky.

01-7700

BJ weld is fixed until you need the next fix - i have found my mileage to vary with increasing age.

bigaaron

ill let you know how it holds up. You will have to forgive me if I fail to update you in the next 4 to 5 years. I hope it lasts that long.

bigaaron

its still hanging in there

bigaaron

original post 7-6-2020

update on my jbweld repair. Its still hanging in there as of 5-31-2021 (almost a year) used 4x4 all winter. Put about 15k on it. I'll let you know if it changes.

bigaaron

original post 7-6-2020

its 11-0802021

still no issues with my jb weld repair going into another winter. I will let you know if anything changes

ultimatenoobie

Thanks for the updates.

arshooter

When I was 16 I had a motorcycle and it got hit and that put a crack in the crankcase and engine oil was dribbling out. I literally laid the motorcycle on it's side so that the oil flowed to the other side of the crankcase, then cleaned the oil of off the outside of the engine and cleaned the area good with gasoline and then smeared over the crack with regular electrical grade silicone RTV. I left it to cure overnight and then used it as normal for the next three years before trading it off. I never had a moments trouble with it. I didn't grind out the crack, use any special cleaner or any special sealer, just what I had on hand. YMMV.