Author Topic: Fixing Duramax Allison transfer case pump rub holes  (Read 173 times)

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Online srcarr52

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Fixing Duramax Allison transfer case pump rub holes
« on: June 01, 2015, 11:59:33 am »
For once I got to save my own butt with the tig welder. I'm in process of rebuilding the turbo, trans and transfer case for my '02 Chevy 2500HD when I ran into a problem with the transfer case. The used car dealer said they put in a new transfer case when I bought it but it looks like they just epoxied the holes and slapped it back together.

All 4 bosses have deep gashes, 3 actually made it out of the case.





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Online srcarr52

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Epoxy removed and bead blasted, ready to weld.





Welded.




Online srcarr52

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Finished and bead blasted again.








Offline Nathaniel Vansickle

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used car dealers would never do that
5105H and 6400H in stock

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Offline aclarke

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Slime balls!  Nice repair...

Online srcarr52

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I was pretty pissed when I found it. I really want to call them up and chew them out. Maybe they'd think twice about doing it again.

I asked the local trans shop if they ever have them welded. No, they just put on a new case side, $300 part.

Offline Nathaniel Vansickle

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would be lying if i said i had never seen it done before. My cousin has a used car lot and that is minor compared to some of the things i have seen come through there. that seems to be a common problem on those chevy transfers. we have replaced 3 or 4 of them for  that problem in the last few months. never knew what caused it, we find the leak and tell him the transfer is junk. install a "new" junkyard transfer and move on. They are getting expensive though. Last one was around $600 IIRC. couple years ago we were buying them for $200-300. might have to look into fixing them for him
5105H and 6400H in stock

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Online 3000 FPS

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Nice job Shaun.   It just goes to show you cannot trust people to do things correctly.  What ever the reason.

Be glad you have the talent to do this type of work and save your self a ton of money.   I know over my 64 years I have saved a bunch of money by being able to do a lot of my own repairs.   

I was wondering did you do any preheating or just used the tig after bead blasting.   
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Online srcarr52

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Nice job Shaun.   It just goes to show you cannot trust people to do things correctly.  What ever the reason.

Be glad you have the talent to do this type of work and save your self a ton of money.   I know over my 64 years I have saved a bunch of money by being able to do a lot of my own repairs.   

I was wondering did you do any preheating or just used the tig after bead blasting.   

No preheat, mag melts pretty easy so you can keep the heat in the whole part pretty low. The rest of the casting never got too hot to touch by hand.

Offline aclarke

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$300 is cheap for such a big chunk of Magnesium...

 

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