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Unread 11-30-2014, 08:29 PM   #1
wyomikey65
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Cracked tranny and overdrive unit removal

Howdy All!! I have a 96 GC with the 42re tranny. Here's my story.......
I was doing a simple transmission cooler line change. Well....this just happen to be the week the temperature here in Casper Wyo. got down to -27 degrees F. Long and short....while replacing the old quick connect on the return line at the transmission....with a Dorman 800-610 the transmission cracked......never even tightened all the way. I'm guessing fatigue from the cold. The crack extends under the overdrive unit housing. I have tried JB weld with no luck leaks pretty well.

My plan is to remove transfer case and loosen up the overdrive unit and pull it back a couple inches ; plans are to braze the aluminum to seal the crack.

Q: Now i know if i completely remove the ODU i may run into trouble,....but will i be okay if I'm just pulling it back a few inches at most?
How long is the shaft?
Thanks for your help!!

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Unread 12-01-2014, 05:36 PM   #2
wyomikey65
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Bump......
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Unread 12-01-2014, 09:25 PM   #3
ZeeJay1997
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maybe someone with some hands on experience can tell you but it looks no longer than about 1.5" in the drawings.

be sure to support the OD unit when you slide it back because it can damage the intermediate shaft if left hanging.

I'm no expert on the matter, never bazed aluminum and havent seen the crack, but my knee jerk opinion is that if the crack is leaking fluid, it is from a passage or seal.
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Unread 12-02-2014, 04:43 AM   #4
coralman
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Also I think the is a gasket between the two housings. What are the chances of separating the housings without tearing the gasket? Then you have another leak?
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Unread 12-02-2014, 04:53 AM   #5
wyomikey65
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Quote:
Originally Posted by ZeeJay1997 View Post
maybe someone with some hands on experience can tell you but it looks no longer than about 1.5" in the drawings.

be sure to support the OD unit when you slide it back because it can damage the intermediate shaft if left hanging.

I'm no expert on the matter, never bazed aluminum and havent seen the crack, but my knee jerk opinion is that if the crack is leaking fluid, it is from a passage or seal.
The crack is along the base of the threaded hole at the inlet on the non-pressure side of the transmission....it's visible and accessible.
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Unread 12-02-2014, 04:57 AM   #6
wyomikey65
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Quote:
Originally Posted by coralman View Post
Also I think the is a gasket between the two housings. What are the chances of separating the housings without tearing the gasket? Then you have another leak?
Yeah I know there's a paper gasket between the two. I'm wanting to move the ODU as lil as possible.......I hear they can be a b***h to put back on if removed completely and incorrectly.
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Unread 12-02-2014, 08:08 AM   #7
Marcos
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This may allow you to repair without touching the OD case:

http://www.sonnax.com/parts/1815

You may also need a tap, which will raise the cost of the repair somewhat.
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Unread 12-02-2014, 05:41 PM   #8
wyomikey65
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Quote:
Originally Posted by Marcos View Post
This may allow you to repair without touching the OD case:

http://www.sonnax.com/parts/1815

You may also need a tap, which will raise the cost of the repair somewhat.
Hey Marcos....thanks a bunch for that website. This is obviously a common problem with Dodge/Jeep/Chrysler products. This might just do the trick!!!
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Unread 12-02-2014, 06:13 PM   #9
MrRoundel
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Quote:
Originally Posted by Marcos View Post
This may allow you to repair without touching the OD case:

http://www.sonnax.com/parts/1815

You may also need a tap, which will raise the cost of the repair somewhat.
Awesome source for what looks like an excellent fix. I think you might have saved Wyomikey65's bacon with that one. Good luck to him. If I ever need it, I hope I remember it.
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Unread 12-02-2014, 08:40 PM   #10
wyomikey65
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Originally Posted by MrRoundel View Post
Awesome source for what looks like an excellent fix. I think you might have saved Wyomikey65's bacon with that one. Good luck to him. If I ever need it, I hope I remember it.
Yeah...(Marcos) definitely has given me the best option. The price for the kit is kinda pricey ($90-$154),....but it is exactly what I need...... I really only need the one adapter (42re) and the 1/4" tap. By the looks of it you can't purchase the tap separately. What is sad is that this seems to be a very common problem with all the Dodge/Chrysler/Jeep transmissions. You would have "thunk" they would have fixed this problem ages ago.
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Unread 12-04-2014, 04:55 AM   #11
wyomikey65
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I went ahead and purchased the Sonnax adapter kit; $86 and change shipped through Rockauto. I will keep y'all posted when I do the repair and if it's a success.........fingers crossed!
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Unread 12-04-2014, 06:56 AM   #12
Marcos
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Nice work! I didn't even think to check Rockauto. That's the best price I've seen for the whole kit online.

Be sure to keep the metal shavings out of the case passage when using the tap.
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Unread 12-04-2014, 08:57 AM   #13
MrRoundel
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Quote:
Originally Posted by Marcos View Post
Be sure to keep the metal shavings out of the case passage when using the tap.
Dang, that's a good point. I'm guessing that the kit comes with instructions on what to do and what not to do. What do you do to keep the pieces out? Just back out the tap to clear it every couple of turns?
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Unread 12-04-2014, 01:59 PM   #14
Pierre_r
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Coat the tap with grease, the grease will catch any metalshavings.
Just take out the tap sometimes to clean it and put new grease on it.
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Unread 12-04-2014, 03:03 PM   #15
MrRoundel
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Originally Posted by Pierre_r View Post
Coat the tap with grease, the grease will catch any metalshavings.
Just take out the tap sometimes to clean it and put new grease on it.
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