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  1. #1

    Crack in XLT 1200 Case

    I have just gotten to the point in my rebuild to start putting everything back together and when I was cleaning the cases to get them prepared for the rebuild I noticed this crack. It is not all the way through the case but I am wondering if this is going to cause issues when the motor is rebuilt and if so what steps I would need to take to repair it? Any advice and opinions are appreciated.
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  2. #2
    Looks small. Jb weld works.

  3. #3
    Baypirate's Avatar
    Join Date
    Mar 2014
    Issaquah, WA
    With the pictures you posted, and not knowing more it is difficult to determine what caused the crack. If the crack is in way of a bearing it could be a stress fracture from unusual engine operating conditions, and will get worse quicker rather than later under normal use. I assume the engine is being rebuilt for one of those reasons. If the area of the crack is in an open area it could be caused by unusual stresses withing the engine casing like excess horse power, loose foundation mounting bolt, or uneven improper torquing of the casing halves. All of this will also play a role into how long a repair of any type will last.

    As for repairing the crack. It is all relative to how much money you want to spend. If you want the casing to be fixed 100% you will have to open your wallet. If you want the unit fixed today, on a budget, and play rather than pay you can do that too.

    East Fix;
    Wire wheel all the paint off the out side in the area of the crack to remove the paint and ruff up the surface. The ruff surface will create a profile on the casing material and provide more surface for the JB Weld to bond too (this is good). Remove surface contaminates with acetone, and patch over the crack with JB weld. After the rebuild (be sure to do a casing pressure test) use the engine as normal. Should last through the year or possibly the life of the machine. it is all depending on use, abuse, and original cause of the crack. When the crack is through the block, and the patch has failed you will start to notice oil weeping from the area of the crack. The oil weeping wouldn't initially be large enough to have air leak into the engine casing, But you will see the oil as an indicator of the bigger problem. I would also paint the out side of the casing white in this area to quickly notice any oil leaks.

    Long term complete repair; $$$$$$
    Wire wheel off all the paint, clean with acetone. Use dye penetrant to check the full size of the crack. Using a ball shaped die grinder remove some material along the crack as indicated by the dye. Using the cleaner from the dye check kit, clean the area and use the dye check kit again. Follow this procedure till the crack is fully removed. Once complete TIG weld the casing to build up and replace the material removed from the casing during grinding. TIG welding would limit the heat used to weld the repair and help prevent the casing from warping. After the welding is complete the area may have to be ground and stoned to removed excess material. Finally to ensure a proper fit the casing halves they could be either blue fit together or plan to use a nice layer of gasket maker. Either way this would be a permanent repair and should be performed by a machine shop. When finished the casing but would be good as new. Only reason to have the casing recrack in this location would be if the casing is unusually stressed during use.

  4. #4
    powerstroke specialist mikegp's Avatar
    Join Date
    Mar 2011
    i will have it welded on the outside . that will be a permanent solution, jb weld will do it temporary.

  5. #5
    Myself's Avatar
    Join Date
    May 2007
    North Central Arkansas
    I agree, have it welded by a pro on the outside.

  6. #6
    I have it at a machine shop now getting an estimate to be welded. It was in the portion of the case that I lost a crank bearing on which caused the need for a rebuild so I am guessing it is from that. I will see what the shop has to say and if it is to much to repair I will see if a member has a set of cases for sale if not I will be going to ebay. Thanks for all the advice I really appreciate it!

  7. #7
    Happily Self-Employed WFO's Avatar
    Join Date
    Nov 2005
    Houston, Texas
    I have had this type of crack welded before and every time it is close to the pan rail it has shrunk up the mating surface, causing a gap. I would either try the JB weld if its not all the way thru or unfortunately replace the cases.

    I have had luck welding when its further down, but when they are that close to the mating surface its usually a no go.

  8. #8
    WFO I appreciate the advice and that makes that decision easy I am in the market for a pair of cases

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