I have a crack in my W56 case from where the previous owner of my 4runner must have over cranked the fill plug. When I bought it the plug was stripped and it leaked a little gear oil. I got the old plug off and installed a new washer and plug. I think when I did that, it widened the crack. I know not to JB Weld it, but am not sure what the correct fix is? TIG weld?

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Weld it for sure. I would probably weld a sleeve on it instead of just welding the crack but I tend to over-do things.

Some tips below:
- http://www.pirate4x4.com/forum/showthread.php?t=1041926

You might try draining the case and clean the crack well and then using something like JB Weld in the crack followed by some sort of ring or clamp over the outside to hold the crack closed. Best would be if you can find some sort of steel ring that would be a jam fit over the round part there.

Thanks for the replies. Hard to believe I'm going to have to replace the case for that little bs crack. The repairs seem like just as much work as replacing the case. I don't have access to a TIG welder, so I would have to take it in somewhere. Not sure how much that would cost.

I have this exact same problem, I by no means half arse anything on my vehicle while fixing it, however this is what I did and how it has worked. Just keep in mind, I am purchansing a completely new T/C that is geared so this is why I went this route.

The crack is in the exact same spot, and as you have stated, It was there when purchased, I was informed about the crack. I DID use JB weld to cover the cranck after thouroghly cleaning it, scuff it up with some sand paper (lightly) and let it cure with the plug out. after that, I replaced the plug and washer. I have a very very minimal leak going still but not engough to ever really get on the case it self. This has held in place for 3.5 years with several T/C fluid changes in between. Not a permanent fix, but like I said before, I had plan to get a new case with gears when this one crapped out, it just hasn't yet!

If it were mine, I would clean it very well, de-grease it as well as possible, the dab some JB weld-type epoxy on it. I would find some sort of sleeve that just barely fit over that thread boss, then possibly have the sleeve welded to the bolt, so that when you tightend the bolt, the sleeve snugged over the boss. Or just sleeve it and let the bolt retain the sleeve.