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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.
- If it turns it is a problem with the transfer case.
- If it doesn't it is a front axle engagement problem ( this is what you seem to have, the transfer case is engaged and will drive the front shaft mine was a key on engine off test ).

- If the front drive shaft does not turn :
•With the truck running ( with front wheel back on the ground ), switch from 2WD to 4WD and back again, the vacuum shift motor should move the lever on the front axle.
sscullys_185.jpg
-- If the vacuum shift motor does not move:
1.Check for vacuum on the lines while shifting between modes. Pink vacuum line is 2WD mode, Light Blue vacuum line is 4WD.
2.Check the fuses for the 4WD system and the solenoids.
3.Check the vacuum lines from the vacuum shift motor to the solenoids on the firewall.
sscullys_187.jpg
4.Check the vacuum lines from the solenoids to the vacuum reservoir box behind the battery.
5.Check the vacuum reservoir box for cracks.
6.Typical solution is the vacuum lines ( to the solenoids or to the vacuum shift motor ) are cracked or the vacuum shift motor has a cracked diaphragm and has water in it.
7.Could be the shift plate contacts in the transfer case are corroded / not making good contact, and not activating the solenoids.
sscullys_186.jpg

Usually the case is cracked vacuum lines from the solenoids, the next common is a cracked vacuum reservoir box, and 1 time I have seen the mount for the vacuum disconnect motor broken ( motor floating free so it could not push against the axle )
sscullys_188.jpg

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Assuming you installed the correct starter
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You will have to have the bell housing TIG
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1 Answer

I have tried all kinds of things to get my 4x4 to engage and still nothing these are what I have done vacuum actuator replaced transfer case actuator motor the Transfer case control module and the transfer...


Make sure all the fuses are good on the circut.look in owners manual under (fuses)..I have also found bad/cracked/leaking vacuum hoses going to the actuators

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1 Answer

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More than likely it's a broken motor mount. Motor twists under torque and is stressing to transfer case. Possible driveline but highly doubtful.

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2 Answers

2002 chevy 2500hd has water in transfer case


need to drain fluid and refill with clean oil.

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1 Answer

Broken adapter between transfer case and transmission . We're assuming it's an adapter and it's completely cracked open with fluid pouring out. What could have caused this?


Sorry friend there is no adapter between the transfer-case and transmission, if your lucky it's the transfer-case that is cracked and not the transmission housing. What could cause this??? Going over something high and the transmission hitting causing the housing to crack, or a worn transmission mount. Good luck and keep me posted, be glad to know you got your Suburban running again. 

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1 Answer

1996 chevy blazer housing between transmission and transfer case cracked are there seals on the rear of the transmission and front of the transfer case in the housing?


No. The out-put shaft on the tranny goes straight through and there are no seals except for the transfer case out-put shaft. There is only a gasket that seals the two cases.

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1 Answer

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Replace the overdrive unit case. It isn't hard to remove the parts and switch them. OR replace the overdrive unit with another one. I can tell you how to disassemble the unit. You will be suprised how easy it is.

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99 Durango 5.2L - Had minor vibration while driving for less then a month. Two days ago all the ATF was left on the side of the highway. Service tech said the bolt on OD between the transmission and...


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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