Welding Transfer Case

[AMC1]

I removed the rear case & retainer as a unit. The case was leaking - not the retainer. They both have hair line cracks but the retainer concerns me. It is cracked inside & out at the speedometer inlet. It goes all the way onto the outer lip of the mating surface but not the mating surface itself. Interesting the factory did not apply sealer to the mating surfaces - only 1/8  inch around the circumference on the inside lips. I’m not sure a good welder would want this job. Any thoughts appreciated.

[mudkicker715]

I doubt it. The metal sounds like it is stressed. Most likely it crack again. Any idea on the cause of the crack? Any bad vibrations?

[AMC1]

No problem with the way it sounds & drives. It sits mostly -  actually only 24K original miles on an "83 isn't a lot. Gaskets start to leak however. I see a lot of fellows dismantle Transfer Cases etc. & am wondering if they come across stress cracks & how much of a  concern it is?

[mudkicker715]

I have torn apart cases. I never seen what your describing, or cracks at all.  I even broke the chain offroading. No cracks to the case.

[AMC1]

It surprises me that you haven't come across any stress cracks. The aluminum is very light weight so I wasn't shocked about it. If cracks are not common to see then maybe there are good spare parts available out there. I'm going to check today to see if I can see any in the front case.

[eaglefreek]

I had a 229 crack on me.

[AMC1]

Your cracks look similar to mine. The Front Case looks good on mine. Yesterday I tried a dry fit of the Rear Case onto the Front. Wouldn't you know it many parts fell out. I had to read the TSM to see what I was doing. The Rear Output Shaft, Roller Bearings & Coupler all came out. I'm having a tough time getting the Shaft & Bearings past the Main Shaft O-Ring on to the Main Shaft. The Bearings are no problem but I'm wondering if the O-Ring has swelled enough not to allow it.