Leaking 5 Speed Question

[AwdGte]

I have searched and can't find any info on this ...

I just purchased a 93 GSX 5 speed, that had what was said to be a leaking axle seal, turns out someone cracked one of the transfer case bolts, I assume they drove a bolt down that was too long, with an impact gun, and when it pressed against the part that bevels, it split it. Its a hair line, but leaks a lot when warmed up and the fluid is more viscous.

It leaks from that bolt hole pretty bad. Instead of putting the transfer case back in, etc etc, I pulled the trans out. I can TIG weld, but have no idea how to get that front case (bell housing) off of the rest of the trans ... any tips?

I'll replace all 3 seals, and I guess use some sort of bond, maybe RTV to seal the case back up?

Has anyone had this happen to them, or purchased a car like this?

 

[AwdGte]

^^^

 

[pneumo]

You'll have to take the whole tranny apart to get the bellhousing off. Sorry, there's no easy way to do it.

The bearing for the front diff is right behind the axle seal, so you'll have to be carefull when welding in that area. I'm no expert in welding, but I know the weld needs to penetrate deep into the case so it's strong enough, and at the same time you don't want to overheat the case and distort it. Those are contradictory goals, which is why welding isn't recomended.

Yes, RTV is used when sealing the cases together. Make sure to clean off the old RTV and use some acetone or brake parts cleaner on the case edges so the RTV forms an oil tight bond.

I've been on these boards for some time and I've never read of anyone else with the same problem as you have.

Good Luck!

 

[AwdGte]

Thank you for the reply

It is cast, so its more of a pain to weld then aluminum tubing or bar, but I've been welding for a while and should be ok, time will tell.

I took the trans to Brad Brooks to disassemble and assemble, I don't have the time to put it back in and then realize I have forgotten to do something correctly with the assembly of it, so hopefully that part will go smooth.

If it works, I'll post so that if anyone else encounters it, they can find this through a search

 

[pneumo]

Since Brad is taking it apart, you should ask him to show you how the front diff bearing fits in the case. The bearing is in the same area you will be welding, and you don't want to fill in the bearing seat with a welding bead. There is a little bit of room to build up a thick bead next to the bearing so you can reinforce the area for better strength.

 

[AwdGte]

ok, thanks, thats a good idea!

Since Brad is taking it apart, you should ask him to show you how the front diff bearing fits in the case. The bearing is in the same area you will be welding, and you don't want to fill in the bearing seat with a welding bead. There is a little bit of room to build up a thick bead next to the bearing so you can reinforce the area for better strength.

 

[AwdGte]

The crack when down into the bearing location for the axle. Instead of welding it, and then having it trued again, I just had him put another bell housing on it, works fine