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pistonfields

Member Since: 29 Mar 2022
Location: Zurich
Posts: 72

LT230 blind hole crack

Hi there!

I'm rebuilding my transfer case. Boy, the previous owner / mechanic did a poor job. It's a mess.

Click image to enlarge

Click image to enlarge

As visible in the pictures two blind holes have cracked due to hydrolock. They have put sealant inside the holes... good job, must have been a professional. I wonder why they used screws at all, as everything was glued together with tons of sealant.

I'm about to check if the threads are still tight enough to hold the bolt properly but would like to know from you guys what to do next. Just leave it as it is (if the bolts do not wiggle) or get it welded? I have an AC TIG welder but do not plan on do that with TIG / by myself. I have welded cast aluminium in the past but know that it will crack again due to stress - at least with my level of skill. I plan on sleeving the case so I have to do some mill work anyway; the project is taking longer than I thought. As usual... Honestly I'm happy if I can keep work to a minimum.

Cheers from Switzerland,
Marc

29th Mar 2022 7:29am

Angus_Beef

Member Since: 30 Apr 2015
Location: Oslo
Posts: 434

2015 Defender 110 Puma 2.2 SW Corris Grey

Grüezi Marc

That's unfortunate. Personally, I would be inclined to replace that case with a sleeved one from Ashcroft. They are only £85 plus a £100 core charge.

Cheers
Dave Roaming around 🇳🇴🇨🇭

29th Mar 2022 7:44am

pistonfields

Member Since: 29 Mar 2022
Location: Zurich
Posts: 72

Thanks for your reply. Yes that is indeed a good option. I wanted to sleeve the case myself as it's a fun task, but now with the cracked holes it's a different story. I might look into that but would still like to know if some of you just ignored it and had no problems so far...

29th Mar 2022 8:19am

X4SKP

Member Since: 29 Nov 2013
Location: Berkshire
Posts: 2295

2010 Defender 90 Puma 2.4 SW Stornoway Grey

Hello pistonfields ... and welcome

TIG welding Cast Aluminium Alloy often only postpones the inevitable...

I agree with Angus_Beef replace the component and put the past bad workmanship behind you.

The effort to get to this area and rebuild the Transmission generally makes any 'not best practice'
a false economy... (IMO)

Good Luck SKIP
https://www.defender2.net/forum/topic83242.html

29th Mar 2022 8:58am

Linds Hanson

Member Since: 16 Jan 2021
Location: Cornwall
Posts: 486

Probably best to fit Wurth threadserts with locktite

29th Mar 2022 8:59am

pistonfields

Member Since: 29 Mar 2022
Location: Zurich
Posts: 72

I have now ordered a replacement housing to fix the transfer case as son as possible. I might try to weld the cracked case just for fun at some point in life

thanks again for your help!

1st Apr 2022 9:52am

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