Bugsy

If this was my daily...
I'd go off to the marine or auto parts and get an expanding rubber plug until I could get it welded or a new/used case.
Like this with t-handle or nut.

JUSTINTHECOASTIE

My thoughts exactly

S2K.Danny

The washer I used was new oem from dealer, it was deforming under very little pressure which I thought was strange.. & I never torque drain/fill plugs to full spec because I'm aleays paranoid of THIS happening, so I had it set to 15ftlb & it snapped right before it even got there.
The fill plug for the differential was on so ridiculously tight that I had to use a 2 ft breaker bar to get it loose.. So I'm assuming the guy who owned it before menhad a tendency to overtighten everything including the drain plug for tranny, causing stress cracks over time..

I like the idea of the expanding rubber plug, I might give that a try as a temp fix
Right now I need to start getting quotes from aluminum welders.. I really don't want to remove the tranny again as it was a major PITA, & I'm assuming it's gonna cost a fortune to have a guy come TO the vehicle & weld it =/

JUSTINTHECOASTIE

Good luck buddy

S2K.Danny

A tech at my work said that the MTF may eat the rubber & cause problems? Is this a possibility, or is he on crack? ha

Slows2k

The washer in your pic was tightened over 15ftlbs. It has extruded to the root of the threaded shank of the drain plug. What kind of torque wrench was being used? May be time to get it calibrated. 15ftlbs can be easily achieved with 1/4 drive ratchet.

S2K.Danny

I suppose it is possible I forgot to put the new washer on & left the old one on the plug, I'll look around & see if I still have the new one somewhere.. will check the torque wrench tomorrow, its a smaller one, I think it goes from 24"lb to 260"lb & had it set to 180 inch/lbs but it cracked before it got there, not much force at all.

chris_barry

If you are getting it welded get a AN8 or 10 alloy welded on ( also called dash 8 or dash10 or sometimes AN fitting). Put the appropriate cap on it to seal up. It will probably end up welded on at angle over the broken off section. Just make sure its not hanging down where it can be hit on something.

S2K.Danny

Well, temporary fix is in progress...
Drove all over the place until I found "Tacoma Screw" had a 14x1.5 tap. Picked up the tap & a 14x1.5 bolt that was 35mm in length.
Tapped the threads almost an inch further in, about 5/8" past where the crack goes. Flushed out the tranny & got all of the shavings out, brake cleaned it out, etc..
Used Red Thread Locker all over the new bolt & tightened it in as far as it would go, it's sitting up against where the washer would normally seat.
Now I'm waiting 24 hours for it to cure, then going to JB-Weld the crap out of it, so this will be hopefully permanent..
If it works (fingers crossed), it'll get me by until I can afford a tranny rebuild (probably time to replace a couple synchro's) and put it back together in a new case.

Billman250

listen...go get a product called form-a-thread. Made by loctite or permatex, cant remember which. Been 15 years.

trans will be good as new. trust me