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Break in ZJ transmission housing


terrawombat
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Anyone have any pointers on how to fix this break? This is around the fitting for the return line on the trans cooler lines. From a 46RE transmission on a '98ZJ.

 

 

 

Threads are boogered so even if I epoxied it back on, I don't think I could get a good seal.

 

Any thoughts?

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1.Clean everything up real good. Put the fitting in place. Clamp it so it doesn't move. JB Weld the shet out of it.

2.Smooth the surface up a little, taking the jagged hump off. Drill and tap the hole making sure you don't break thru into the tranny.

3.Replace the tranny.

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Whole new trans over a trans return line? Yikes.

 

It's in such an awkward spot that I'm not sure someone who could weld aluminum would be able to get a full weld all the way around. I think I'll try the JB weld approach first. If that doesn't work, I may just JB weld this hole shut and use one of the many other capped off holes on the trans housing as the return. Problem is all of those holes are in awkward spots and are smaller than the original hole...

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I think, (which can be hazardous) I'd plug the original hole by taping the narrow hole and plug it with a bolt.

Then redrill the hole above the original outlet and then thread it. Reattach original line.

 

It's just an idea, chances of it working, I do not know.

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I think, (which can be hazardous) I'd plug the original hole by taping the narrow hole and plug it with a bolt.

Then redrill the hole above the original outlet and then thread it. Reattach original line.

 

It's just an idea, chances of it working, I do not know.

 

Take a look at the first picture (the one with my hand in it). There is a threaded plug above the hole. I need to do some research and see what it is and where it goes, but I may be able to plug the original and use that one for my return drain. It's on my list of options, anyway...

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I think, (which can be hazardous) I'd plug the original hole by taping the narrow hole and plug it with a bolt.

Then redrill the hole above the original outlet and then thread it. Reattach original line.

 

It's just an idea, chances of it working, I do not know.

Can't do that. That's solid metal above the hole and there's a test line behind it that he would drill into. The cap above the broken hole is a clutch test fitting so can't tap into it. I checked all the caps and they are all for something, mostly test ports, so they can't be used. All you need is a way to return the fluid back into the trans. Find an old case, stripped. find a place where you can place a fitting. Biggy here is making sure you don't interfere with any internal parts. Maybe even direct into the pan. Maybe use the dipstick hole, tube.

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I've actually got a spare 46RE case in my shop that came out of my 5.9L ZJ and it's partially torn down so I can always look at that for reference. Tapping the pan wouldn't be a bad idea, but I wonder if the return being submerged in fluid would have any ill effects.

 

Thanks for the info on the test ports. That wouldn't be a good place to put a return line LOL.

 

No drain plug in the 46RE pan, although I should probably add one while I've got the access to it...

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