Screwed up cutting the transfer case for the low range gears, is this fixable? How bad did I botch this…

[hisandhers80s]

I managed to cut the case through to the shift fork tube. When I rotated the case to change my cutting angle, the case dropped off my board that was keeping it level. I finished the cut at an angle and barely broke through the fork tube. Is there any way to fix this, or do I need to look for a case 1/2 to replace it? Looks like it is around $260 from Partsouq plus an arm, leg, and kidney from fees, shipping, and tariffs. I also assume that what the diagram says w(*VCD) ) it means the case had the viscous coupler?

 

[MissahPapaJ]

Shoot dang that sucks but also 260 ain’t bad and you know what not to do now.

 

[MissahPapaJ]

Also on early 2001-2006 Chevy transfer cases where it would wear through on the passenger side. If they were being cheap asses I’d pull the case and clean well and JB weld that hole. Wasn’t right by any means but I think those case covers were over 500$ at the time.

 

[Cruisers and Co]

I managed to cut the case through to the shift fork tube. When I rotated the case to change my cutting angle, the case dropped off my board that was keeping it level. I finished the cut at an angle and barely broke through the fork tube. Is there any way to fix this, or do I need to look for a case 1/2 to replace it? Looks like it is around $260 from Partsouq plus an arm, leg, and kidney from fees, shipping, and tariffs. I also assume that what the diagram says w(*VCD) ) it means the case had the viscous coupler?

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Just file it down. As long as the shift fork doesn’t bind you’ll be fine

 

[Kernal]

Someone good with AC TIG welding aluminum could fix that, cost ?? $100-200, but then there's also the shift fork tube that would need to
be brought back to the correct dimensions.

Contact Japan4x4 for a new rear case??

Easiest would be to pick up a used transfer case, then you'll have spare hard parts for the future??

 

[hisandhers80s]

Just file it down. As long as the shift fork doesn’t bind you’ll be fine

Whew, am I glad to hear this!!! I was thinking that might be the case, but you know how it goes when you mess up. Always fear the worst!

 

[Cruisers and Co]

Whew, am I glad to hear this!!! I was thinking that might be the case, but you know how it goes when you mess up. Always fear the worst!

As long as it glides in and out smoothly when lubed up it’ll be fine

Just knock down those burrs and test it. That section is not load bearing it just holds the shift rod. If it slides back and forth easily you’re good to go. Worst case you’ll have to replace it.

 

[MikePL]

If you have a TIG, it's a 15 minute repair plus some filing. If you want someone to do it, you would pay $200 or more. So probably buy the new part if it really is that surprisingly cheap.

 

[jonheld]

Looks like it is around $260 from Partsouq plus an arm, leg, and kidney from fees, shipping, and tariffs.

You could probably pick up an entire used transfer case for that.

 

[CharlieS]

What I'd do in this order: TIG weld it, buy a used transfer case, or buy the new part.

I know the "just run it" advice is from a pro who does this kind of work all the time, and I am just a guy on the internet, but personally that would be my last choice.