Cracked bolt ear on block

nicknorth11 · Apr 17, 2013

I was removing my transmission and in the process ended up cracking this ear on the block. The crack goes all the way through to the threads. I think this bolt goes through the transfer case and then the block, but I'm not positive about that. Also, while backing out the bolt, The threads stripped. I have two questions about this.

1) Is it absolutely necessary to fix this, or will I be safe without it? (Please don't respond with, "It there for a reason." We all know there is plenty of stuff on our cars that we can live without.)

2) If I must fix it, should I have it welded before or after I try to tap the threads?

19Eclipse90 · Apr 17, 2013

Typically, you would want to weld it before you tap the threads.

You would also want know that bolt does not thread into the block at all; it goes through the hole in the block and threads into the transmission. The transfer case is not involved with that bolt. Make sure the threads are clean in the transmission, weld that up and ensure the bolt still clears, get the correct dowel pin and ensure that it fits correctly, and be on your merry way. Yes, it must be fixed.

BogusSVO · Apr 17, 2013

Before you weld it, or have it welded, grind a V groove on the crack about 1/3 of the thickness of the ear.

Also preheat the area with a torch before you weld, welding cast iron and chasing cracks sucks.

Junfan · Apr 17, 2013

You could not be in better hands than BogusSVO. His posts here are invaluable to many of us and good luck getting it fixed.

twicks69 · Apr 18, 2013

Also, use 99 nickel stick or rod to weld the cast iron.

clipto · Apr 18, 2013

My friend has a block that has that except for its totally busted off down the middle of that bolt hole. Does that ruin the whole block for use?

twicks69 · Apr 18, 2013

clipto said:
My friend has a block that has that except for its totally busted off down the middle of that bolt hole. Does that ruin the whole block for use?

Does he have the broken portion still? If so, then you can weld it back on, drill, tap for helicoil and install a m10x1.25mm helicoil.

If not, well, you better look at options for a solid rear mount or fashioning up a different mounting point and cross-member if you are going to use it.

TSI_AWD_FTW · Apr 18, 2013

The bolt that runs through there, and threads into the bell housing of the transmission. The bolt for that is smaller that the transmission bolts also. The threads inside of that cracked piece are for bolting the block up to an engine stand, and in that case you'd use a transmission bolt.

greene · Apr 18, 2013

BogusSVO said:
Before you weld it, or have it welded, grind a V groove on the crack about 1/3 of the thickness of the ear.

Also preheat the area with a torch before you weld, welding cast iron and chasing cracks sucks.

exactly what i was going to say, clean the surface well , and grind a groove along that crack it helps to burn the area together nicely during the welding process. once its finished tap your threads

HIGHPSI4 · Apr 18, 2013

You will not have to worry about the threads because the smaller bolt goes through the hole and threads into the transmission. If done correctly, and the threads were needed, you should not have to retap or clean up the threads.

nicknorth11 · Apr 18, 2013

Wow! Great advice and very fast. You guys are awesome. I appreciate all of your help!

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Cracked bolt ear on block

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