Outer Limits 4x4 Board

G'day I have a 80 series with a 1hz and it's part time. The gearbox has had a slight leak and i went to change the oil when I noticed where the drain bun is has a crack in the alloy gearbox case, I rang the gearbox shop and they said it's pretty common and the only way to fix is replace the outside case which isn't cheap, has
Anyone else had this problem and how have you fixed it?

I have had other gearbox housings welded with great success.
Should be able to weld it up without dismantling the box possibly, but best to talk with a skilled welder about that as the oil contamination may make it hard.
If the crack is not a structural problem then you might be able to clean it up really well and epoxy it up to stop it leaking

If its the outer transfer case that Im thinking of. Its common because backyard mechanics have played with it. If you dont line the rectanglar head up that spins the pump correctly and then try and tighten the bolts. It with crack it.

its also common when the alloy washer isnt used or the fill plug is over tightened.

It can be welded in the car but for best results pull it off and clean it down.
any semi compentent alloy tig welder should be able to do it

I had a similar thing with the drain plug hole on my 80 series gear box, some tool had tightened the drain plug too much, stripped the thread and cracked the housing . I took it to a transmission place and they welded the crack and put a thread insert in the drain hole, cost about $100.