Reason for asking. I recently rebuilt my trans after some issues and when installing the c-clip on the countershaft I put the plug back in and it popped a piece of the threads right off. So now there is a chunk of the threads/case missing around that plug. Which will surely leak.

What are my options in fixing it. It's a pretty small piece so I didnt want to try welding on it and gum it up worse. Anyone ever welded/patched a honda trans case before?

 

yes you can tig weld it.. i have an LS integra transmission that the top part of the housing got completely fractured it was two large pieces and one small piece and i had it welded back together and you can defitnatly see where it was welded but the transmission itself does not leak and works great...

if you broke around where there is threads though that will be harder... the reason being that its going to be almost impossible to weld it without it warping the bolt hole... so u would need a tap to straighten out the threads after but for the perticular plug ur talking about i dont think theres a tap in that size and thread type... maybe if u put the plug on and weld it while the plug is in so the plug keeps everything straight that could work too... just make sure u have someone competent in welding do it...

but to confirm yes you can weld a cracked cast aluminum transmission case.

 

thanks. I've been searching around and it looks like it can be done. Just not many people do it.

I was def gonna put the plug in there and hold the piece while they tack it. Hopefully with enough care we can pre-heat the area and prevent it from warping too much. I just want to trash a whole case over such a small crack.

Thanks for the reply!!

 

Well, the threads will need to work to make the transmission serviceable, so it will most certainly need to be as straight as possible. If it doesn't line up exactly, you will be retapping and probably losing some threads.

The case takes a lot of heat to weld though (it's thick and large). Not to mention, it needs to be very, very clean. Usually you can make some passes over it with the welding torch to remove some dirt that conventional cleaning cannot remove.

Next time you put that in, you don't need to make it so tight that it cracks. Honda Bond seals it. All you need to do is snug it up. I barely even tighten them for fear of cracking the case.

 

the oil must be baked out first of the porous casting.

 

yes it can be done i had to have a trans case welded where a clutch/ pp bolt backed out and punched a hole in the bellhousing side and leaked all the fluid out

it took him a while and you def have to burn off the oil residue before welding anything or it will not be pretty

 

what's funny is I wasn't even more than half way in. It must've gotten something in one of the threads and cracked. I think there was a small crack there already since there's a dent already around that plug from someone dropping it or something. Must've been before I got this motor set.

Oh well, I'm gonna try one of those quick weld/soldering aluminum fix things and see if it'll hold some fluid. Worse case I can probably coat it in hondabond and be ok.