ok, i thought i had a leaking cooler last week.
packed the car away and had a break from it.
Today i finished work early and decided to sit and evaluate the job of removing the cooling shroud and generator in order to get to the oil cooler.
After some time tracing the oil path i have discovered that the case has sprung a leak 20 mm beneath the stock oil sender . Its a hairline crack and while the car idles it starts seaping until it flows freely then pools in the pulley tinware and is flung everywhere..
Does anyone know how i can repair the crack ???
Is the case toasted and ready for scrap??

I know the sight and the feeling... The case is toasted.. Get another one

You may be able to fix it with jb weld.

Grind out the crack to a V.

Buy an adaptor to screw into the sender hole to screw the sender into later.

JB weld the adaptor into the case. JB weld the V.

Success is directly related to how clean you can get it including the V.

May save you from a rebuild.

its not in the thread but approx 20 mm below the sender thread.
Its in a place in which you cant get access to.
its beneath the sender the location is more overhead beneath.

bet u using a tapered sender shank vw use a straight sharft after market are tapered

i spoke to a very knowledgeable fellow regarding my case leak.
What i was told was, this happens to cases that get machined inside to create space for strokers.
Machining the insides of the case can weaken it significantly and usually oil galleries or areas about oil galleries and plugs are the first point of hairline cracking..
So im still looking for a decent alloy case..