2004 Chevy Silverado 1500 5.3L 4x4

[amy269]

I have a Chevy Silverado 1500 4x4 with a 246 transfer case. Something happened an I have a gash an a small hole n outer casing is there anyway to fix this so I can just buy a rebuild kit? I was already tricked into buy another transfer case that does not fit my truck an can't get my money back. So can I repair an rebuild the one I have?

[asilverblazer]

I patched a hairline crack in one with JB-Weld. If I was in a bind, pull the T-Case out, disassemble, thoroughly clean around the hole inside and out. Rough up the case with sand paper, apply epoxy and make sure it overlaps the opening to the inside. Cover it with some tape to act as a backing material, then smooth off the outside so that the epoxy overlaps the opening on the outside. Let it cure really well. Remove tape and clean thoroughly, especially any sanding debris. Put it back together and hope for the best. 

 

I think a salvage unit would be a better bet...