Cracked transfer case-?

Thanks for clearing that up for me jeep junkie, the cable is in place if this is what an engine stay cable is in the picture. It's the bottom cable that is attached to the bell housing and to the transmission crossmember.



yes it is about 18 inches long.

 

wow, thats what that thing was for.

 

The engine stay cable which limits the forward thrust of the engine when hard braking will reduce stress on the mounts. It also will help eliminate chatter when backing up. Do you have a good mount under the transmission to cross-member? That crack sure looks like it was caused by too much down pressure past the point of the torque (Z) mount. The one with bushing above and below the cross-member. Be sure there is no steel insert inside these bushings.

 

Yup ! thats the one !

 

Hey Walt, what bushings are you talking about, for the transfer case or the transmission? I have pictures posted already of the bushings for the t-case.

 

Don, I have two single stick cases and a twin stick case, mine are different castings. The single stick has two detent shafts and the twin stick has one detent shafts. One of the single stick cases has a broken ear on it and I wanted to use the twin stick case, but it is a different casting.

 

The casting with the two caps on the back will work for a single stick and twin stick 18 transfer case as will the case with the single cast protrusion for the shift rails. The twin caps on the back is a provision for model 20 transfer case shift rails.

 

Ok I'm just throwing this out to see if it will stick. While waiting to see which direction I should go, I figure it wouldn't hurt to try some home brew patch work with JB weld.


i took a grinder and removed a thin layer until it was new metal showing, then I took a drummal with a cutting wheel and cut across the crack, not too deep, but hopefully enough to give the JB weld something to grab. Blew it off and cleaned real good with acetone. Put a thick layer of JB weld on. Filed down the bottom even with the t case. Just waiting on a gasket to come In to reinstall the bottom cover.


i know I may get some flack for trying what seems to be half@&& patch work, but it needs replacing anyway. So if it works it's a $6.00 fix that may buy me alittle time until I can decide on what to do.

 

If you put a Girdle on that bottom pan rail.............as was previously mentioned you may have something.

 

Rick,
I think you may find twin stick case you have is the small index case for a T90 and they are a little different from the later cases.
What I was trying to say was that the large index cases are the same whether they have a single stick or twin stick setup on the front bearing casting.

Don

 

People have been patching Jeeps for decades. The Jeep responds well to frantic , last ditch efforts

 

These bushings that you have mounted above and below the cross-member and bolt to the (Z) bracket. This is there to stabilize the sideways movement of the drivetrain and limit the torque movement. If these bushings have a steel insert inside them, they will act like a solid bolt which can cause the D-18 case to be over-stressed.

 

Hey tarry99, can you explain what you mean by putting a girdle on it?

and no Walt, the bushings don't have any metal in them, however, I the red polyurethane bushing
is pretty stiff.

I can only imagine some of the "handy work" the military had to make due with to keep jeeps running in WWll.

 

You are my kind of Jeeper!

 

Just my .02, but a previous poster offered you a case for the cost of shipping. IMHO your repair will not last long and is liable to leave you stranded who knows where. Take the offer and rebuild your new case with the old internals if they are OK. What you have there now is a boat anchor. Also, if you go back and look at the bottom picture in post #25 it sure looks like there are some chipped teeth on the large intermediate gear. Maybe it's an illusion. Also, in the same post, the upper picture show mis-alignment at the crack in the case. I can't see how this would make a serviceable case unless you corrected that along with the repair.

 

Those are chipped teeth....won't they only get worse from use over time if neglected?

 

I think we are looking at drops of oil, not chips.

But I agree the shaft alignment is probably screwed up now.

 

Thanks posimoto, I've inspected the gears and didn't notice any chipped
teeth, but you never know I could've missed something. I'll inspect it again tomorrow. And you are correct the crack caused a little misalignment, however, the gears still turn free and there is clearance between the housing and the gear.

Yes I've been offered a housing, but don't have the experience to take out the old internals to put in the new/used housing. I will be looking to eventually replace this t case with one that has already been rebuilt or is in good working order. In the process of looking now. I appreciate your advice/opionon. I'll try post some better pictures of the gear teeth tomorrow.