Outer Limits 4x4 Board

Was doing a service on my 80 series cruiser yesterday and undid the gearbox drain plug to find that it had cracked around the plug hole and come right off.

What do i do about this ?



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Drain the oil out of the box, find someone who is really confident in welding cast alloy components, get them to weld the broken bit back in.

Drill and re-tap, heli coil if you have to as well, the thread and it should be all good!

that looks like a real pain in the arse!

welding it is gonna be an absolute pita aswell.

Big pain in the arse ! I was about to do a 400 km trip to Chinchilla tmw !

quick fix: seen this one done, drilled out, tapped then screw in a reducer. Other than that get it done properly

So if i get the cast alloy bit welded back and retapped... can it be done while it's still on the car or do i have to remove the gearbox ?

Mad Cruiser wrote:So if i get the cast alloy bit welded back and retapped... can it be done while it's still on the car or do i have to remove the gearbox ?

Should be able to do it on the car. Just got to make sure you clean all the oil from where ur welding.

It looks like the hole is deeper than the bit that broke off. Have you though about getting a short bolt and some loctite or sealant for a quick fix?

looks to be a fair amount of thread inside the box ,what about grinding the whats left of the broken thread off and using whats left

otherwise welding it will be a nightmare due to what oil in the box is floatin around will drip when your tryin to weld wich after tryin to do on steel the other day doesn't work the oil gets hot n makes new holes

plus cast alloy is mainly crap material and is really hard to make a good clean weld stick

either way good luck

You may be able o get away with some liquid steel or devcon to stick the treaded bit back in until you can get it welded...

Getting it welded up.....

Thanks everyone for the suggestions and help !