welding my transfer case ...

[zyka1]

Most of you know the problem, dumb design, a broken clip that allows the steel pump to rub a hole in the aluminum case, (see below).
Question one- My question is can this be welded??
Many say it cant, but I found this article that makes it seem possible. ( http://www.magnesium-elektron.com/data/downloads/DS250JO.PDF)
Using a new pump saver wont seal the hole, or will it, wont this still leave you with a leaking T/case fuild problem.
Question Two - Has anybody else had a one hundered % fix for this problem ??

 

[zyka1]

here is some more information on welding magnisium alloys as used in transfer cases and other car components :

Welding Processes for Magnesium Alloys -
The various processes employed for welding magnesium alloys are
1. Gas Tungsten Arc Welding (TIG or GTAW)
2. Gas Metal Arc Welding (MIG or GMAW).
3. Resistance (Spot) Welding.
4. Gas Welding.
5. Brazing.
6. Other processes (e.g., Pressure Welding, Forge Welding, Electron beam welding, TIG spot welding, Stud Welding and Adhesive Bonding).
http://www.welding-technology-machi...ys/welding-processes-for-magnesium-alloys.htm

also check out this clip on alloy welding with durafix rods, it amazing stuff !!
http://durafix.co.uk/pages.php?&pID=10
Can a crack or hole in a mangnisium alloy casted Transfer case be welded, or not??

 

[Sasquatch]

I`m not sure if it`s the best idea but i know it works.

My brother had his transmission replaced under warranty by a dealership and they somehow busted a hole in his transfer case about the size of a golf ball while doing the work.

It turns out that they epoxied the hole AND NEVER TOLD HIM ABOUT IT.

Two or three months after he got the truck back he was installing a catback exhaust and he noticed the hole and it held up very well for that size hole.

Needless to say he raised hell and got a new case but it`s probably not a bad idea to use epoxy for the tiny hole in your t-case.

 

[Young28]

Welding that with a tig will be a pain in the ass b/c it has to be SUPER clean. You could use a mig with the aluminum gun attachment and clean it up a little. Going the mig route it has to be clean but not as clean as trying to tig it.

 

[javelina80]

Over on dieselplace (duramax forum) many people have had success using JB Weld.

 

[zyka1]

Thanks guys for the feedback !
Sasquach, whats epoxy they used it may come in handy?

Its also good to know welding is also an option, I wonder why nobody has opened up a bussiness in welding up t/cases its such a common problem.

 

[Young28]

Thanks guys for the feedback !
Sasquach, whats epoxy they used it may come in handy?

Its also good to know welding is also an option, I wonder why nobody has opened up a bussiness in welding up t/cases its such a common problem.

No money in it most likely.

 

[Sasquatch]

I`m not sure what type of epoxy they used, My brother wasn`t too concerned about finding out what it was. He just wanted a new t-case from the scumbags.

Like Javelina80 said, JB weld would probably work well.

 

[yooformula]

Mine has a crack and this is what I did to seal the crack over a year ago. I scrubbed the area with med grit sand paper, used some rubbing alcohol on a rag and soaked the area then heated it with a small butane torch, then used Liquid Steel. Over a year later and no leaks, sucks though that the inner seal failed and now oil is coming out the vent tube of the trans.