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Unread 08-11-2012, 03:27 PM   #1
Alheim
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1995 YJ Wrangler 
 
Join Date: Apr 2002
Location: nyc
Posts: 507
Rotting aluminum AX15 casing, ever seen this before? With pictures.

Hey folks. I'm in the midst of a 4.0 swap, and while I'm at it I'm replacing the seals on my AX15 & transfer case, as well as swapping over to an external throwout bearing setup.

Anyway, on the bottom of the transmission, on a area that is normally covered by the transmission mounting plate (the 'torque plate'), I found a spot on the aluminum casing that was rotting / corroding away. Once I removed the torque plate I lightly chipped away at the aluminum until I had removed all of the flaking, then wire brushed the spot.

The corroded spot:



This is on the bottom of the AX15. Here you can see it relative to the rest of the transmission and transfer case:



I've never seen aluminum do this before. Any thoughts? How thick is the trans casing at the spot? Anything I should do to stop further corrosion?

Thanks for your time.

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'95 YJ 123bhp 4-banger powerhouse.
UPDATE: 2.5L ENGINE RETIRED; she was still running strong at 212,000mi.
4.0 swap in progress.
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Unread 08-11-2012, 03:36 PM   #2
Jeepsr4me
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Aluminum does corrode. And that spot there may hold salt and crud. Sand it down with some aluminum oxide sand paper and clean then paint with some good paint. That area would have already cracked if it was thin. So you got lucky enough to catch it.
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Unread 08-12-2012, 08:45 AM   #3
Alheim
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Thanks.

I suppose I knew aluminum can corrode but haven't seen it to this extent before. You're right, this was in a spot that had a ton of dirt & salt wedged in there, between the torque plate and the transmission.

Any paint suggestions? At the moment I only have Duplicolor primer & engine paint on hand.
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'95 YJ 123bhp 4-banger powerhouse.
UPDATE: 2.5L ENGINE RETIRED; she was still running strong at 212,000mi.
4.0 swap in progress.
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Unread 08-12-2012, 08:59 AM   #4
Jeepsr4me
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Get some self etching primer, after that what ever color you want.

I seem wings on aircraft have worse corrosion than that, on the inside structural member.!!!
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Unread 08-12-2012, 09:58 AM   #5
lovett86
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kinda looks like some one had heated that up with torches at one point for what ever reason
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its a rusty one

http://www.jeepforum.com/forum/f22/90-yj-frame-swap-build-up-1434246/
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Unread 08-12-2012, 11:04 PM   #6
imstillatwork
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1993 YJ Wrangler 
 
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can you get a closer, clear photo? that looks like something has been rubbing, or someone melted it. can't tell from the distance though. weird??
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