[the.silverbullet]

Ok so my trans cooler lines were leaking again and i decided to remove them and replace them with Hyd Lines. After i removed the old lines, i decided to pull the brass fitting in the trans. With my luck the fitting snapped off with little force. I was able to remove it with a easy-out. My big problem i now have is the case around the threads is cracked. I tried my best to seal it but nothing is holding. I bought a couple different items and they did not work. I try JB Welding the outside and that didn't hold, so i JB welded the inside with the fitting and it still leaked. Not sure if the weather is causing the JB Weld not to cure its been a high of 30 and been a real pain to work on the truck. So here are some ideas:
1. weld the crack.
2. Cut the crack and threads off and re drill and tap.
3. Recase the trans.
4. Swap my auto to manual
5. or theres a fitting that is supposed to fix it. http://www.sonnax.com/system/instructions/22000-01_01K-IN.pdf
Its hard to tell but if you look at the second picture you can see the crack starts on the left and go's through the threads around the bottom and back up the other side.

 

[cummins6sp5.9]

That's going to be difficult to fix. Because that where the two halves were casted together. Right at a seam. Only idea I have is would be clean area with brake-clean. Non chlorinated. Can be had at your favorite autoparts stores. Then, get some pipe sealer. Install . Other then that.Do a manual tranny swap or get a tranny case.

 

[pmccue]

mig , grind and smoothe, retap , pipe sealer

 

[SNKEBIT]

Clean it REALLY good with something like brakecleaner, Tig it shut and drill, tap out. I don't know how easy that would be in the truck tho.:S:

 

[the.silverbullet]

To weld it shut i would think i would need a spool gun. It would be hard to Tig it only because its to deep and small of a hole. The other idea i have is to cut the case flush and drill and tap. The case is solid for a inch past the threads.( the dealer said they have done this before.) I need to pull it apart and see how far the crack goes.

 

[mathews8pt]

I have seen one cracked there. We pulled the trans and had it welded. That is NOT a cast line on the front half of the trans. Thats the way i would go. Second would be cut and re-tap if the crack isnt very long.

 

[the.silverbullet]

That's what I'm going to try. I have to go out of town for a couple days so I'm going to drop it off with a transmission shop.

 

[dozer12216]

If shop pulls apart and welds. The entire case is probablly avaliable for about same price as welding. Benefit is you know it fixed. At some time the fitting was over torqued during install.

 

[the.silverbullet]

I end up taking it to the shop and having it recased. It was the same price to just recase it as it was to try to fix it. Thanks for the ideas!!