Can you post some pictures? I wonder; how it got cracked? Was the car; ever wrecked? 
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Crack is a couple inches longer than what you see. After I cleaned it more, I was surprised
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OUCH! Thats hard to tell; if it would give you mechanical problems. I wonder; if it would possibly; weaken the structure of the trans over time and keep traveling from mechanical stress? That section of the trans case; could be repaired (welded) or just replaced with a used section of the trans case (more cost effective?). When I had my 02M apart; it wasn't too hard to remove and replace the trans halves; if you found another used trans case half. Personally, I would have a hard time putting it back in; especially, since you could probably find a perfectly good used one for cheap; at a pick 'n pull junk yard. If you can find a low milage one; it might be a blessing in disguise, as yours @ 200k is probably worn out? I guess, that is a judgement call you need to make but I would have a hard time putting that back in (unrepaired/cracked); when better used ones are cheap and easy to get (most junk yard have golfs, jettas, new beetles laying around).
PS: now that the trans is out; you might see if the clutch fork, that the throwout bearing is connected to, is bent. This is a common problem; that causes shifting problems and they also wear out over time, @ 200k it might be due. They make upgraded versions; that are welded to reinforce them to keep them from bending.
https://www.google.com/webhp?source...=1&espv=2&ie=UTF-8#q=02J+upgraded+clutch+fork
With the prices; that people want to repair/wled a trans case half/bell housing; it might be cheaper to get a whole used low mileage transmission? You could remove the bellhousing; take it to a welder and get a estimate and see what they say.
http://www.ebay.com/sch/i.html?_odk...MISSION+CASE+HALF+FRONT+BELL+HOUSING&_sacat=0
Good discussion thread; NOTE: a new/used bell housing would require the preload; to be checked and shimmed if necessary. (the cost of having a professional do this for you; would probably push you into the same amount of money; a whole used trans would be).
http://forums.tdiclub.com/showthread.php?t=430352
I guess, that is a judgement call you need to make but I would have a hard time putting that back in (unrepaired/cracked); when better used ones are cheap and easy to get (most junk yard have golfs, jettas, new beetles laying around). PS: now that the trans is out; you might see if the clutch fork, that the throwout bearing is connected to, is bent. This is a common problem; that causes shifting problems and they also wear out over time, @ 200k it might be due. They make upgraded versions; that are welded to reinforce them to keep them from bending.
https://www.google.com/webhp?source...=1&espv=2&ie=UTF-8#q=02J+upgraded+clutch+fork
With the prices; that people want to repair/wled a trans case half/bell housing; it might be cheaper to get a whole used low mileage transmission? You could remove the bellhousing; take it to a welder and get a estimate and see what they say.
http://www.ebay.com/sch/i.html?_odk...MISSION+CASE+HALF+FRONT+BELL+HOUSING&_sacat=0
Good discussion thread; NOTE: a new/used bell housing would require the preload; to be checked and shimmed if necessary. (the cost of having a professional do this for you; would probably push you into the same amount of money; a whole used trans would be).
http://forums.tdiclub.com/showthread.php?t=430352
Bummer, well; keep us informed, as your search continues.
Cool, keep us informed; as you progress further!
Yup, the axle shaft flange ends are different bolt spacing, so either the flanges need to be swapped between the trannys, or the matching axles have to be taken out with the donor transmission. I got the axles from my brother's car, and have one replaced. I'll get some pics posted eventually when I get it back together. Having leakage for some reason from the power steering fluid reservoir now. The joys of DIY, always something new showing up.
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