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Cracked transfer case, can this be wielded? - Cars & Trucks

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It can be welded by the best welders out there
using TIG Welding, but you got too much porosity
& oils in that material & I doubt that is ever done to
a transfer case. Would have to come apart,I guess
your aware of that
You get a Used Case or complete exact same year,model
as you have, from a Salvage Yard or a Transmission Hard Parts
Supplier & their a lots of both out there
I once owned a trans shop & I don't like salvage yard parts
In the case of your transfer, you don't have any choices
Buy a used unit or just the correct case & build it from scratch
If possible, always do ALL your own work,not to save money,
to get it done correctly & know what you have.
I would never & have never, in 50 years, ever let anyone touch
any of my vehicles parts.
I only use new parts or rebuild what came with the vehicle.
FIRST --- why did it crack,has to be a reason & that has to
be resolved FIRST

Posted on Jul 21, 2013


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Got. A 2003 f150 4x4 got problems with 4 wheel drive locking in and stay in drive shaft turning front wheels not

Operationally vacuum shifts the front axle between 2WD and 4WD mode. The GEM ( Generic Electronics Module ) applies ground to the solenoid needed for the mode selected on the switch ( for ESOF ) or when the transfer case shift lever is moved ( MSOF ).The contact plates in the transfer case signal the GEM that the transfer case is engaged, and the Vacuum solenoids need to be activated ( either 2WD to 4WD or 4WD to 2WD ).

Lift and support the front of the truck so the front wheels are off the ground ( take safety precautions, chock wheels, jack stands, etc )
Key on, engage 4x4 and try to turn the front drive shaft.
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4.Check the vacuum lines from the solenoids to the vacuum reservoir box behind the battery.
5.Check the vacuum reservoir box for cracks.
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If it's just the bolt that is cracked, replace the bolt, if the transmission housing is cracked. You may have to replace the transmission housing if not the transfer-case housing. If the crack is not to bad you can call around who can weld aluminum and have them weld a bead over the cracked housing, at worst your going to have to replace the transmission since it's cheaper then taking your transmission apart to replace the housing or the transfer-case. Good luck and hope this helps. Keep me posted be glad answer any question you may have. 

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