I’m rebuilding my S3 4.2 (1986 XJ6) and realized kind of late that the sump has a crack that was previously repaired, if you call it that:



What is my best option short of getting a replacement sump here? Get it welded, or will epoxy be sufficient?

Thanks!

 

It could be welded up, but I expect that getting a replacement sump is cheaper. An XJ6 sump should be easy to get, I'd try David Bodger at Everyday XJ. He's a great guy to deal with.

 

Since I’m lucky enough to have this sump removed from the engine, I figure adding some JB Weld from the inside should form a pretty resilient seal. The previous repair was from outside only:


If this is a bad idea someone please tell me now! 😅

 

Epoxy will do it.

 

JB Weld will absolutely work. BUT! I think you'd have to go insane cleaning it. And probably should get it hot somehow while cleaning, maybe even an oven in order to get oil out of crack.

 

Also, there are different types of JB Weld. Make sure the one you are using is for high temperature. 5 minute JB Weld is not the one you would use there. As Andy said you have to heat that area to get the oil out of the crack. If not it will fail eventually. JB Weld does not adhere to oily surfaces.

 

When 2002 Ford Windstar van came to us, it has been Terribly abused and had a cracked sump to show for it. As NONE were available, and Heroic effort was required to replace it anyway, I set about "gluing it up."

Yes, cleaning was a Nightmare as it was alloy and on the bottom, but I couldn't drive it like it was so had nothing to lose. First item was to scrape off the band-aid cr@p some cheapo shop had slathered on previous to our ownership, which lasted long enough to get it out the door (which it could have been harder to remove had it not already come mostly loose on its own).

I used on it, followed directions, and it Never leaked at that spot again.
(';')