Cracked oil pump output threaded boss on 964 case

[tholyoak]

Picked up a used 964 engine this past fall that apparently has ~140k KM on it but was removed several years ago due to leaking like a sieve from pretty much everywhere. Finally took the case to be cleaned at the machine shop and they found that after removing all the gunk, the threaded boss for the oil line that attaches to the case for the pump output was cracked as shown in the pictures. Not sure if this could have happened by over tightening or not but as you can see the crack extends down into the threads and across the top surface. Anyway, I am seeking input into if this can be repaired and by whom.


Thanks,
Todd

[Mark Henry]

My bet is a hard impact at one time. I don't know for sure but I imagine it can be welded and re-machined, but you will have to see if the repair cost is less than just sourcing another case.

[Henry Schmidt]

The way to fix this issue is to bore the existing boss out, insert a new custom made boss and weld it in place.
Then deck the new boss/fitting to correct any warping caused by welding.
We could do it but it would cost 3-$400 and take 2-3 weeks.
good luck

[tholyoak]

Thanks to both of you for the input.

This was going to be a simple rebuild project to entertain me during this winter. Based upon the prospect of this new repair bill, the economics may stipulate that it makes more sense to part this thing out and find something else to play with. I think the shipping costs back and forth to California for you to do the repair Henry would double the cost at least and I don't know if I would be able to find anyone in Canada with the experience to perform such a repair.

Todd

[Charlie V]

Shipping would be about $100 each way. Use a storage tub, pack foam around the case and duct tape it closed.