Update on 3204 oil cooler leak and ???

I went out to see what I was up against to fix the broken mounting boss for the oil cooler. Good news! It is a separate bracket but the boss that broke can be threaded deeper. That's what I'm going to do since it already has the hole and just needs deeper threads in the boss. I was thinking of epoxying the broken piece back on cause I still need a spacer. I don't really want to weld it but could if it would be a much better repair. I also found out why it broke. It had been previously broken and was missing about 1/8" inch so the oil cooler had nothing to bu-t against against when the bolt was tightened. Also both of the mounting bolts had been cut shorter with a hacksaw. I know Cat sometimes uses odd length bolts but no one mentioned anything when I had the engine rebuilt about 6 years ago. I can get a tap to grab enough to hold the broken piece on till the epoxy dries. I can also use epoxy to build it up and then file it to the right height. Does this sound like a good solution or should I use something else for a spacer? If I use the broken piece for the spacer should I leave the threads in it or drill them out since the deeper threads in the boss will do the holding? Thanks in advance.

if you can get Devcon its an industrial strength JB Weld...my dad brought some home from work for me years ago...they were using it to resurface turbine bearing surfaces...i used it to repair a hole that had been drilled into #1 cylinder by a DIYer tryin to replace a water pump on a old Ford 6...saw that car 10 years later and it was still goin.

That broken boss might have been something they didn't want to talk about.
Drill out old thread in broken part.
Later Bob

Yah, I don't know if the original bolts only grab about a 1/4" of thread and it broke when they worked on it or if it was broken previously. Maybe both bolts were made longer after the first boss broke? I still think they should have mentioned something and/or used a couple washers or something for a spacer. Apparently not all 3204's use a separate bracket that the oil cooler bolts to. I think it's an oil galley from the injection pump to the oil cooler. I got the disassembly pages and it shows the oil cooler bolting right on the block. At least now I have an explanation why it broke.

I put a bolt in the broken piece and wrapped some masking tape around it. Then I put some epoxy on to build it up. I let it set till it got stiff and then turned the bolt so it wouldn't get glued in. I got the bolt out easily this morning and amazingly the masking tape came off even easier from the epoxy. It was still sticky! The epoxy isn't fully cured but it says to wait 24 hours. Seems to hold on the cast iron OK though. I'll drill it out and file it to the right height.