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Have seen some ATV fluid drips on the floor of the garage. Seems to be coming from a hairline crack just below the drain plug on the back of the transfer case of my 03 Expy. Suggestions on repairs would be appreciated. Thanks,
Last edited by chuter; Mar 27, 2019 at 04:42 PM.
Reason: Forgot to add model year.
Somebody probably over-torqued the drain plug there, and over time it produced that stress crack. If it's time to drain the oil in the case do that, and wrap the plugs with yellow teflon tape. The plugs should just be snugged down, not cranked down with a big ratchet. For that crack you already have I would just use some JB Weld to fill it in.
You'd probably have to put the JB Weld in the crack and let it dry before removing the plug. Once the plug is out the gap will close. Also, I would run a bead of RTV all the way around the hub (as a glue) and put a hose clamp on it just to keep some pressure on it which might help stop the crack from spreading more.
I had a "slightly larger" crack on the bottom of my DR650 and repaired it with JB Weld and JB Stick, and have ridden it for hundreds of offroad miles since. Just be sure to rough up the material with sand paper and clean the area with solvent. You can "stop drill" the end of the crack to help stop further propegating. I would ride this thing anywhere tomorrow!
Yes, it's a thick aftermarket one too, at least 3/16" thick. I was jumping off the rain diversion bumps that tractors make on mountain roads, going up Saddleback Mountain here in Orange County. I hit a pyramid shaped rock sticking out of the dirt right at the oil drain plug hole in the skid plate. Behind my skid plate, I had a piece of 1/4" carbon composite for extra protection which is stronger than the aluminum. Well my fat *** bottomed out, punched the hole in the case, broke the composite, and flattened the steel tube frame in the pic too.
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