transfer case repair?

I have a 1997 k1500. I recently got her stuck, and as a result of being stubborn, I twisted off the front drive shaft. It snapped the shift cable. And now have a hairline crack in the transfer case. In the front of the case, near the bottom about 4" long. Does anyone know if the shift cable is a dealer item? Also, can anyone tell me if the crack in the transfer case housing can be repaired?
Thanks in advance,
cartman0223

You could most likely scuff/ruff the crack with a small grinder and cover it with JB Weld, Scuffing will assure a good bond. Not sure about the cable.

Get a used/rebuilt case. There are lots of them out there. Generally, aluminum cannot be repaired/welded and is very unforgiving of cracks.

The cracked case is severely weakened and is a big safety hazard. You could lose all your fluid and seize the rear output shaft. This would lock up your rear wheels and likely cause an accident.
Or the case could rupture, allowing the transfer case chain to loosen and jam the rear output shaft, resulting in an accident.

aluminum cannot be repaired/welded .


Hmmm, Guess you never heard of Heliarc ?

First, aren't the newer transfer cases magnesium? I saw a warning label on one indicating that it was, not sure if all are. Magnesium is extreemely flamable, and can be ignited using only the heat of a propane torch.

Second, even if it is aluminum you will never get a good weld. Aluminum must be heated to several hundred degrees to get a good weld. Even if it didn't have to be pre-heated, you would want to get EVERY drop of fluid out of it to avoid starting it on fire. That would mean removing it from the vehicle, and if you're that far, you'd be better off buying a used one and selling the cracked on for scrap.

If the crack was caused from the shaft smacking against it, I would try to repair it. I would use Permatex Ultrablack, but do scuff the area, as was said. It will flex slightly, which means it won't break like an epoxy could.

If it cracked as a result of too much torque, I would definately replace the transfer case.

And how stuck were you that you twisted a driveshaft!? I've been stuck where I needed two winches (8,500 lb and a 9,500 lb) on jeeps that were straped to trees and never twisted one, and that was with dirt/mud pressing against it. Must have been a fun day :)

Sorry it took me soo long to update... the best i can tell, the shift cable is dealer only, that was the only place i could find it. $104.oo out the door. As for the transfer case, most people say just to use jb weld... including local mechanics. a used transfer case would cost $450.00. I really don't know what to do with it.
Also, J-Ri, the driveshaft was a napa reman purchased about a month and a half ago... for a 2000 tahoe(napa mislabel)... installed backward by Shadetree auto, another local mechanic. Napa warrantied the shaft, but not the resulting damage.

http://www.saturnsurplus.com/differentials/differentials.htm

how many do you want. found a few good sites when i was thinking of keeping my old 85 chevy pu. you will fine the price is very good for what you get.

If you want one with a warranty,go with a Jasper and Jasper does do transfer cases too.Jasper warranties them for 3 years,does upgrades to them and you can take it to any Jasper dealer for warranty work which they do pay for labor and want the old parts back for the warranty work.The transfercase is probally Alumininum and take it to someone that is a very good tig welder.Welding Alumininum is best welded up with a tig welder.