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#Post#: 58426--------------------------------------------------
Fixing Duramax Allison transfer case pump rub holes
DIR By: srcarr52
Date: June 1, 2015, 10:59 am
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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.
HTML http://i1133.photobucket.com/albums/m599/srcarr52/DMaxTransCase/IMG_4193_zpslsz9k7un.jpg
HTML http://i1133.photobucket.com/albums/m599/srcarr52/DMaxTransCase/IMG_4200_zpsos8fyboa.jpg
HTML http://i1133.photobucket.com/albums/m599/srcarr52/DMaxTransCase/IMG_4196_zpsg6xkdtib.jpg
#Post#: 58427--------------------------------------------------
Re: Fixing Duramax Allison transfer case pump rub holes
DIR By: srcarr52
Date: June 1, 2015, 11:02 am
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Epoxy removed and bead blasted, ready to weld.
HTML http://i1133.photobucket.com/albums/m599/srcarr52/DMaxTransCase/IMG_4208_zpszi3lol9s.jpg
HTML http://i1133.photobucket.com/albums/m599/srcarr52/DMaxTransCase/IMG_4202_zpslkg9tztf.jpg
Welded.
HTML http://i1133.photobucket.com/albums/m599/srcarr52/DMaxTransCase/IMG_4210_zpsrvdqcu8a.jpg
HTML http://i1133.photobucket.com/albums/m599/srcarr52/DMaxTransCase/IMG_4212_zpsvb0jetj0.jpg
#Post#: 58429--------------------------------------------------
Re: Fixing Duramax Allison transfer case pump rub holes
DIR By: srcarr52
Date: June 1, 2015, 11:04 am
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Finished and bead blasted again.
HTML http://i1133.photobucket.com/albums/m599/srcarr52/DMaxTransCase/IMG_4214_zpsadu7nzmy.jpg
HTML http://i1133.photobucket.com/albums/m599/srcarr52/DMaxTransCase/IMG_4216_zpst9pygqkk.jpg
HTML http://i1133.photobucket.com/albums/m599/srcarr52/DMaxTransCase/IMG_4217_zps5m5d8ddv.jpg
HTML http://i1133.photobucket.com/albums/m599/srcarr52/DMaxTransCase/IMG_4215_zpsc1upias4.jpg
#Post#: 58434--------------------------------------------------
Re: Fixing Duramax Allison transfer case pump rub holes
DIR By: NathanielVansickle
Date: June 1, 2015, 3:15 pm
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used car dealers would never do that
#Post#: 58435--------------------------------------------------
Re: Fixing Duramax Allison transfer case pump rub holes
DIR By: aclarke
Date: June 1, 2015, 3:28 pm
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Slime balls! Nice repair...
#Post#: 58437--------------------------------------------------
Re: Fixing Duramax Allison transfer case pump rub holes
DIR By: srcarr52
Date: June 1, 2015, 3:51 pm
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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.
#Post#: 58439--------------------------------------------------
Re: Fixing Duramax Allison transfer case pump rub holes
DIR By: NathanielVansickle
Date: June 1, 2015, 7:05 pm
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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
#Post#: 58440--------------------------------------------------
Re: Fixing Duramax Allison transfer case pump rub holes
DIR By: 3000 FPS
Date: June 1, 2015, 9:05 pm
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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.
#Post#: 58445--------------------------------------------------
Re: Fixing Duramax Allison transfer case pump rub holes
DIR By: srcarr52
Date: June 2, 2015, 8:47 am
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--- Quote from: 3000 FPS link ---
>
> 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.
>
--- End Quote ---
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.
#Post#: 58449--------------------------------------------------
Re: Fixing Duramax Allison transfer case pump rub holes
DIR By: aclarke
Date: June 2, 2015, 2:57 pm
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$300 is cheap for such a big chunk of Magnesium...
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