hole in transfer case :(

i have a00 expy that a ujoint broke on the highway and the front driveshaft broke lose. ive just started the inspection of the damage (its pouring rain here this weekend and im doing it outside)
i noticed that when the driveshaft broke lose it punched a small hole in the front of the transfer case around the size of a quarter. im wondering if this is bye bye for the truck and transfer case? or can i close it up with some jbweld? doesnt seem like its cracked around it just a clean hole in the casing. also doesnt look like this part holds fluid, just sort of a bell housing.
my plans for this truck are to get it useable and trade it in. im way over my head on this thing and have spent way too much money repairing it over the last few years...i still owe 2k on it :frown:
i can get some pictures of the damage if the sun comes out...maybe tomorrow or monday, in the meantime id like some advice. thanks

You got a hole in the transfer case? There was metal where that hole is now. Where did the metal go? I'm thinking it might have gone INSIDE the transfer case. Verify that there is no debris in the transfer case or you will be looking at greater problems. As far as using epoxy? I dunno, If I had to I would try it, but if I had some extra cash, just get a new one. Besides your probably going to hav eto take the transfer case off to verify there is no debris in it. Thats what I would do atleast.

EDIT They do make some pretty tough epoxies now days. They even got steel reinforce epoxy, thats what I would use if I was going to do this. But you gotta be sure there isnt any debris in the case

i actually recovered the broken piece. it was laying on the skid plate. so i dont think there is anything in the transfer case.
i tore the wreckage out today. broke the back yoke and ujoint, broke both fuel lines at the flexible part, tore two parts of wire (one with wires going to o2 sensor, and one with 2 wires yet to be determined) bent trans linkage, ruined trans linkage cable, ruined neutral safety switch.

so far ive, straightened shift linkage, pulled driveshaft, pulled neutral safety and fuel lines.

i have new neutral switch,ill grab shifter cable from salvage yard, fuel lines im going to grab from salvage yard. im just going to replace from filter up, luckily im good from the quick disconnect on both lines, driveshaft 25 bucks from salvage with end yoke. ill replace new u joints on it. i patched hole in transfer case with jb weld (praying transfer case is actually ok...wont know till i try to drive it i guess) going to fix wires tomorrow.

anyone have a schematic for the wiring near/over the transfer case? im wondering if the other 2 wires go over to the passenger side o2 sensor out of that same harness?

pray for me :runaround:
did i mention i still owe 4k on the loan for this truck? :swear:

I have been dealing with transfer case issues as well and have been learning a lot with my research. 98 Expedition.
I am curious, did the problem you had, cause the hole in the transfer case, or did the transfer case cause the problem you had?
The transfer cases are Magnesium (if that helps). Is it possible that your pump seized? There is a tab on the pump that wears a groove in the case with age and it is possible that it could wear through the case itself. After that, the pump would just spin and not pump oil through to all the parts causing them to seize and lock up.
The other thing that happens is the shift fork breaks inside these cases causing all kinds of turmoil. Usually caused by the holes that the shift rail slides into in the case halves being worn out causing the shift fork to bind.
If you need a cheap transfer case, I have found them reasonably priced at car-part.com