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Busted out Transmission Cover Bolt Threads.

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Old Oct 27, 2024 | 08:45 PM
  #1  
mr.vls's Avatar
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Default Busted out Transmission Cover Bolt Threads.

I managed to bust open the face of 2 of the transmission bolt threads on the transmission side. The bolts were the 2 forward center bolts where there is a curve for the transmission meets the dust cover. This is on my 89 S15 700R4 Trans. This mating surface is machined cast aluminum., The proper fix would be a new case or find a weld shop that would tackle the repair. I wanted to find a way to a home repair. I tried drilling the 2 holes out for a Helicoil but the spring would not work with part of the face gone. I tried JB Weld but I could not make it work at all. What i finally did that worked was a hodgepodge of an Idea. 1lb of Devcon Steel Epoxy Putty, 18 Gauge Sheet Metal, I piece of steel tubing from an old blow gun. JB Weld Epoxy Putty (Tube), 1/4-20 black Oxide stud.

Step 1. I cut a piece of sheet metal to span the opening of the blown out face of the bolt hole and cut the height to follow the contour of the pump housing ring.
Step 2. Thread the tubing to M8 X 1.25 and cut to the length slightly longer than the bolt thread length.
Step 3. Attache the threaded tubing to the Sheetmetal. Hole one: I drilled the Sheetmetal and spot welded the tube to the sheet metal. Hole 2: Welded the 1/20 stud to the face of the tube and drilled a hole in the sheet meal in order to use a bolt and nut to secure the tube to the sheet metal. (The 2 holes were blown out slightly different and required a different method to attach the threaded tube}
Step 4. I used the JB Weld putty to build a wall from the back of the pump housing to the face of the blown out holes. The purpose was to create a void to fill with the Devcon Steel Epoxy.
Step 5. I test fitting the sheet metal piece with the tubes to each of the holes and made sure that the bottom edge of the threaded tube was flush with the machined face of the mounting surface for the pan.
Step 6. Mix up enough Devcon Steel putty to fill the void behind the Sheetmetal and coat the backside of the Sheetmetal to cover the tube and 100% surface area of the sheet metal.
Step 7. Fill the void with as much epoxy as possible. Place the sheet metal in place and fit it to the blown out hole and the bottom edge of the mounting surface. (Should be plenty of squeeze out)
Step 8. Using spring clamp secure the bottom edge of the sheet metal to the mounting face. Clean up all excess putty.
Step 9. Wait 14 hours. Attached are pictures of the blown out holes. I did not take any pics of the completed repairs as i was just trying to figure something out. The repair is a success. The repair piece is now a monolithic block of steel epoxy from the back of the case to the face of the mounting surface. The pan is attached and all bolts are torqued equally with no leaks. The only issue is if someone wanted to rebuild the trans and remove the pump some of the epoxy would have to be cut back. I consider this a permanent repair/



 

Last edited by mr.vls; Oct 27, 2024 at 09:07 PM. Reason: New Info
Old Oct 27, 2024 | 10:00 PM
  #2  
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Wow!!! Well-done! I'm sure this will be a big help to someone in the future.
 
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