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Reply to "zf output shafts and Half shafts"

David is correct- all you'll do if you try to band-aid the ZF while its in place is wreck more very expensive parts. If someone was to try welding in place, there's a seal 1/2" away from that broken flange, a paper gasket under the plate and the asphalt undercoating on the inner fender panels is flammable. This does not even address the gas tank a few feet away... And it will be close to impossible to surface the resulting weld flat enough to not vibrate your fillings loose unless it's redrilled and machined flat.
PULL THE ZF- it's not difficult and then the problem can be resolved. To practically remove the inner stub-axle with the broken bolt-hole, the ZF must be removed- you'll spend 4X as long doing it in the car, and that's only if you've ever worked on one before. Special tools are required as well as a ZF manual. Finally, all OEM replacement parts, seals and gaskets for a ZF are supplied by exactly one (1.0) place: RBT Transmissions in CA. All other shops that work on ZFs get their stuff from Lloyd, or clean up used parts for resale. There are zero short-cuts and no cheap (new) parts. Sorry....
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