Can anyone suggest an easy remedy for a stupid cock up?

Repair the outside with liquid metal, then search for something called a timesert (ebay or decent nut & bolt type place) far superior repair than any helicoil & has the advantage of being solid rather than a helicoil , which is a bit like a spring in that it has gaps between the threads.

Now that's an interesting idea. I've not tried Timeserts before, but here's some kind soul with a pictorial guide. Not quite the same vehicle but looks like a very similar job.
Land Cruiser transfer case drain plug repair | OlympiaFJ60

Brown said:

Now that's an interesting idea. I've not tried Timeserts before, but here's some kind soul with a pictorial guide. Not quite the same vehicle but looks like a very similar job.
Land Cruiser transfer case drain plug repair | OlympiaFJ60

Click to expand...

I've got a timesert kit, they're brilliant. Don't go that big in my kit tho!


DD

If it is the case itself, you really want to get it welded. If the casing itself is indeed cracked, then chemical metal will work if you clean up and degrease the surface first.

If however the case is cracked, and you repair it with chemical metal, the chances are it will leak again the next time you undo or do up the bolt and the metal flexes.

If the thread is stripped then a heli-coil or timesert will do it.

that looks really good but i dont think it will work. The case itself isnt cracked. just cracked where the threads are if that makes sence. Opened up like a split banana

Kizzeh said:

that looks really good but i dont think it will work. The case itself isnt cracked. just cracked where the threads are if that makes sence. Opened up like a split banana

Click to expand...

Are you saying the split is circling the sump bung thread?

I know exactly what you mean. The only Propper repair is welding. But the bodge it and scarper methods will most likely be good enough for what you need!

Diesel Do said:

I know exactly what you mean. The only Propper repair is welding. But the bodge it and scarper methods will most likely be good enough for what you need!

Click to expand...

That's very reassuring , coming from a mechanic .

I dont mind what it looks like as long as i dont have to keep that bloody gearbox oil in my boot. It stinks!

just waiting for the chemical metal to be delivered. Tried looking for it in the shops and i cant any. tempted to find somone to just weld the thing up.

Halfrauds sell chemical metal, it's usually next to the fillers and rust repair stuff.

OldIrishWulf said:

That's very reassuring , coming from a mechanic .

Click to expand...

Yeah scary thing is the no of cars driving around like it and they haven't got a clue! I don't like it at all but I have seen it done, and it does seem to last until it has to come out again! Then you have to do it again! I try to avoid it happening in the first place
I removed a starter from a narrow boat which had bean professionally refurbed less than a year ago, they'd taken the end off the solenoid cleaned the contacts and stuck it together with chemical metal! Oddly it didn't last very long! I offered to get it done properly but he wants to complain and have god knows what done again! Most garages I've been in wouldn't do it. I have been in one where if you refuse to do something like it the boss would speak to you like you were a piece of **** then do it himself and expect you to sign the job sheet. Never happened! But I never saw one come back. It was usually an apprentice being pushed to earn money that'd do it! Garage now defunct, it was a low time in my life

Diesel Do said:

I try to avoid it happening in the first place

Click to expand...

I'm sure you would never make such a mistake .

OldIrishWulf said:

I'm sure you would never make such a mistake .

Click to expand...

Only done it to the old k series steel sumps. Thread used to strip really easily. But they were cheap and easy to replace apprentice error you soon learn to be more careful! When I worked on alfas they used to hit the road and crack the sump around the plug (worst case rip it out) we got them welded as replacements were horrendous.