Patch for magnesium transfer case?

[Fitz98]

I have a minor issue in my magnesium transfer case for my 98 Expedition.
There is an area where the pump in the transfer case resides. There is a tab that slides in a back to front groove that keeps the pump from spinning, but over time, the tab wears a groove in the case perpendicular to the front to back original groove.
Any ideas what I could safely do to fill in that wear groove?
It will need to be resistant to fluid, but more importantly, I wouldn't want the patch breaking loose over time creating havok around all the bearings and gears in the case.
I would rather do nothing than do a risky patch.

 

[Trav]

It can be built up by welding. I wouldn't trust stuff like JB weld on something like this.

 

[NHGUY]

If its really magnesium,pointing anything hot at it will cause uncontrollable sparks...like the 4th of July.Remember what happens to VW Beetle engine cases when they catch afire...

 

[SteveSRT8]

Originally Posted By: NHGUY
If its really magnesium,pointing anything hot at it will cause uncontrollable sparks...like the 4th of July.Remember what happens to VW Beetle engine cases when they catch afire...


In the early 70's I watched a VW burn on a bridge, the engine burnt THROUGH the roadway and hit the water under the bridge, causing a mini-explosion and continuing to burn underwater!

It was amazing and a bit scary...

 

[Donald]

TIG welding.

 

[229]

Metal sleeve pinned into position.

 

[Trav]

 

[GreeCguy]

I would leave well enough alone. While I understand your desire to have everything "nice and tight" after all the work you've done, I really don't think this is going to give you any trouble in the future, (maybe the distant future). Perhaps you've done this already, but have you done a search on transfer case failure for this given model of vehicle? If it's a common fail after "x" miles, then it could be an issue and perhaps you should look into some kind of patch. However, given the metal you're working with and the nature of the weld, you're going to have to find someone that really knows what they're doing. Just my two cents worth.

 

[Fitz98]

I might tend to agree in this particular case. I have read many many cases where this has been a concern, but never anything that actually caused a failure.
Also, I just compared the groove im my original case half with 170K miles and the one in the replacement I gotwith 72K miles and they look identical, so I am starting to think that is actually intentionally machined into the case th hold the pump tab in position. To further back this up, I did have one other used case where that groove was obviously worn in the arc of travel of the pump, almost to the point where the pump would no longer seat against the case and just spin...that would be a time to address a serious potential for failure.


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