Outer Limits 4x4 Board

Hi all. Let me just say straight off the bat I didn't do it. Anyway, I had to drop my gearbox out thisarv to replace the thowout brg and the pilot brg (the one at the back of the crankshaft). My mate dropped the oil out and when he put the bung back in the thread stripped, the casing cracked and a bit fell out (See Photos)

Any ideas how to repair it? Was thinking of getting it welded. Has anyone had their gearbox casing welded successfully.

Thanks Guys,

Clint
Limited Edition
'95 Feroza

That's bad luck dude !. My roza copped an absolute caining, totally flogged out. When I took to get fixed only one bolt left holding the gearbox to the motor. Suprised the thing didn't drop out, all the bell housing and gear inside was chewed up. You'll get it back on the road, you'd proberly get away with welding it cost alot less than a new one.

Cheers

Jimmy L

The best way to repair it in my opinion would be to get a machine shop to spin up a bit of ally round bar with a tread in it to suit your drain plug, cut the old one off the gearbox and weld your new one over the hole. I've welded a few up like this and any decent sheetmetal or fab shop that welds ally would be able to carry this out. If you just get the missing chunk welded back there is allways a chance it will break off again if you(sorry, if your mate!) over tighten it again.

yes but the entire casting is alum!!!! so take it to a specific alum expert.. trust me on this! it'll be a bit spendy... prolly around $300-400 u.s. for a high quality job. best of luckto you mate.

I am an aluminium expert and any workshop should charge no more than $100 tops. It's ten minutes to make up the boss and ten to do the welding. If they try charging you $300-400 US tell'em to p!ss-off. You could get a second hand gearbox for that! If you can get it down to the Sunny Coast I'll do it for a carton of XXXX. P.M me if you're interested.

wouldnt the welder have to reweld the threads and retap it? thats what i was thinking. this is what i was told when i cracked the thread on the transfer case drain plug. est was $150 jus to reweld and retap.

Thanks wilk, i didn't think of welding on a new boss. I am a Fitter & Turner so i can machine one up in no time at work and get someone in town to weld it on for me.

I am heading down to brisbane in three weeks time, i would get u to do it for then but i am already suffering withdrawl simptoms from not driving the roza for just the weekend.

One more thing, any ideas on how to keep the aluminium shavings out of the box while removing whats left of the threaded section. Was thinking of puting some air in the filler plug and try and keep it blowing out the drain plug.

Looking at the pic, you might be able to remove what remains of the original plug surround, and retap the thread further into the box. It would involve getting a flat surface for the seal to fit against. But you still have the problem of keeping aluminium out of the box. Try your pressurising idea, then flush and reflush the box with some sort of fluid, diesel or kero maybe.

Well i fixed it. Got a mate to build it up with a tig. Redrilled the hole and put a hellicoil in to bring it back to the original thread size.
To keep the shavings out i blew air in the filler plug while drilling and washed it out with kero a few times after.
(The afternoon i fixed it my computer shat it's self. Have just got it back)

Been like this a while now and no leaks

As finished

looks good mate.... feels good to get your roza back on the road huh? man i was suffering from withdrawls for 6 months when my roza threw a rod..... now that i got her back on the road.. i'm a happy camper.. but itching like crazy to get off the paved roads.. but dont know any places to go since i'm in a new city... BUT theres a 4wd club in my area and theres a meeting tonight... so i'm gonna check it out! will take pics and see what i can find for you guys.