WE put enuff detectives on it to
Crack the case..

justin_o_guy2 wrote on 05/10/20 at 15:06:56:

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Classic JOG right there!

SS, we really need to see more pictures.  I suspect that if you look at the case a bit closer you will find the crack more extensive than you think.  

Earlier comments about the starter idler gear are important.  That gear is NOT supposed to have washer on each side.  The washers go on the special kick-back limiter.  If the washers are installed on the idler gear, it causes the cover to pinch the gear.  When the washers are installed on the idler gear it typically causes the starter system to bind.  I suspect it could also result in the case cracking (like yours).

Take pictures of this area.  It might be cracked also.  Based on your prior photos, it seems likely to me that this area will be cracked too.

You also need to be concerned about case bolts.  If the wrong bolt is installed, it can go all the way through the case and contact the starter.  Then as you continue to tighten the bolt, something most likely will break (like the case).

See how a bolt that is too long may protrude and hit the starter.  This is the left hand side.  Also note how the idler shaft bosses are a fixed distance from each other.  Put washers in there along with the gear and you have a metal sandwich.  Something has to give.

The starter drive is high-stress.  I don't think it is a good candidate for a JB-Weld repair.  The epoxy would probably be OK for simply plugging up a leak, but it doesn't have adequate strength to keep things rigid and aligned in the starter drive.

Post some more pictures.  Tell us what you found on the starter idler gear/shaft.  Check out the case bolts that attach the alternator cover and clutch cover.  Tell us if there's a chance that a long bolt was installed in the locations I pointed out.

Hello again. Thank you for the feedback!
It appears that all bolts on the case covers are original, so I don't think one would be too long... unless it was installed in the wrong position. This could be possible since I got it back in pieces and not sure what was done to it while out of my possession (long story). I will double check when putting the cover back on. I didn't come across any extra washers either.

Looking at the starter motor... there are indents where bolts could have possibly been too long. Also, there seems to be an o-ring missing on the left side. Maybe this is why the bolts were not sitting correctly?