Transfer Case (Weld) Failure???

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  • Опубліковано 24 гру 2024

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  • @edt689
    @edt689 Рік тому +5

    1 time, my buddys old ranch tucks front axle shaft came apart and broke a 4 inch round hole in the tranfer case . Took it to the local welder, and he said he can't guarantee it will hold and would not touch it. Next, we Coundnt find one at the junk yard or even new housing for that truck was obsolete, so we went over to local parts store and got JB weld clay type and mixed liquid type. And got a wire mesh. We scuffed it up good and put wire mesh over the hole and applied clay tipe first,let it drye and then we applied liquid type over it and so far its been over 10 yrs still holding t-case fluid in. Last resort kinda deal 👌

  • @TokyoCraftsman
    @TokyoCraftsman Рік тому +50

    That was a great repair, certainly was not easy.
    In my youth I learned to weld aluminum MIG with a spool gun it was not easy, but I learned it, this was in the 1980's, one day at a friend's house I was talking about welding aluminum with a spool gun and how hard it was, my friend's grandmother said that it's much more difficult to weld aluminum with a gas torch....! She was a weldor at one of the Boeing plants during WWII and she welded aluminum with a freaking gas torch... much respect!

    • @JeffMTX
      @JeffMTX Рік тому +6

      Ya never know who you’re talking to eh? ;)

    • @jayusher576
      @jayusher576 7 місяців тому

      I've been in repair situations with thick aluminum parts where that's the only way to get them hot enough to weld a nice big gas tip and some filler rod.. if you think about it a tig torch is doing the same thing just with electricity.

  • @BrianJChelf
    @BrianJChelf Рік тому +1

    This is a great example of the difference between a professional tradesman and an amateur hack.

  • @glennbarker222
    @glennbarker222 Рік тому +9

    You must be the only person in Texas with a space heater running at the moment! Nice work Isaac.

    • @ICWeld
      @ICWeld  Рік тому +3

      I am! haha 🥵🥵🥵🥵

  • @Rogster559
    @Rogster559 Рік тому +19

    Isaac all your effort was not in vain , it gave us a view of what is involved in trying to fix caste aluminium, this one went the wrong way But you can’t fix everything, you are still the master of your profession, all the best from Tasmania Australia 🇦🇺

  • @BrucePierson
    @BrucePierson Рік тому +75

    That was a nightmare. Aluminium castings are extremely difficult to weld at the best of times, never mind trying to repair some else's repair. It looks like that last repair was done with oxy. The case should have been scrapped in the first place and just replaced.

    • @nikxohs3925
      @nikxohs3925 Рік тому

      ua-cam.com/video/k6OH2YpJuEA/v-deo.html

  • @johnjelinek-g7b
    @johnjelinek-g7b Рік тому +17

    Patience of a saint Isaac . I would have definitely told them, well you shouldn't have tried to fix it before, and say you need another case because it would cost more than another case to repair it .

    • @scrout
      @scrout Рік тому +2

      Exactly, I can't believe that a used case wouldn't have been way cheaper

    • @thedeathwobblechannel6539
      @thedeathwobblechannel6539 Рік тому +1

      Junkyard np231 or 242 or whichever it is, would cost less than the weld bill.

  • @kenw2685
    @kenw2685 7 місяців тому +2

    You're the man. One of the best videos ever. Everyone is so used to clean new stuff. This is reality folks.

  • @davedunn2124
    @davedunn2124 Рік тому +27

    Wow. Thats all i can say. Anyone thats ever tried to weld cast aluminum like that knows how difficult that is.

  • @thomas4844
    @thomas4844 Рік тому +4

    Every time I watch you work I learn something valuable. Added to that you manage to inject some humor in whatever the project is. In my opinion, one of the best channels on all of UA-cam. 👍🏼

  • @onemoredeadman
    @onemoredeadman Рік тому +42

    Better effort than the first guy, can't win them all👍

    • @philbert006
      @philbert006 Рік тому

      Shit. Isaac won. Got paid for the job. At least I'm assuming. 😂

  • @Theweldingmillennial
    @Theweldingmillennial Рік тому +21

    That t-case is going on market place and some poor kid will probably think it’s a good deal not knowing it’s welded.
    Wheels, t-cases, transmissions….only do them for people I know and I usually leave them as welded so people can clearly see it’s been repaired. It looks like a decent repair 👍

  • @bentaylor8342
    @bentaylor8342 Рік тому +1

    That "mess" turned into another work of excellence out the door!

  • @63mrl
    @63mrl Рік тому +1

    A lot of work by all parties for a $200 side cover, or $500 complete transfer case. Thanks Issac for the content.

  • @bigmotter001
    @bigmotter001 Рік тому +7

    Nice try Isaac. Your skills always shine through no matter what the outcome is! Thanks for posting and take care!

  • @davemaccarter64
    @davemaccarter64 Рік тому +3

    Isaac, I admire you for even attempting that repair. If you or the customer had had access to a mill it would have been interesting to see if you could have built up weld in the area where the case was warped and then mill it back down to flat with a precision mill. Enjoyable to watch your work in any event.

  • @johnjelinek-g7b
    @johnjelinek-g7b Рік тому +5

    I got to the end . Man Isaac, after all that work it didn't work ?... Still I hope they didn't refuse to pay though . All I can say is you're a hard working humble man Isaac . :)

  • @57WillysCJ
    @57WillysCJ Рік тому +11

    Your work was a success for what you had even if they didn't use it.

  • @ericpetry7525
    @ericpetry7525 Рік тому +2

    Hey sir, I've learned a lot from you. I've been a welding student for about a year. Today I did some arc gouging. I thank you and keep the videos coming.

  • @marklowe330
    @marklowe330 Рік тому +1

    Most cases are so readily available these days that they shouldn't have wasted your time. If they had brought it to you first, you probably could have saved it. Still enjoyed watching. Thanks for your time.

    • @ICWeld
      @ICWeld  Рік тому +1

      I totally agree!

  • @67L-88
    @67L-88 Рік тому +6

    I broke one of those 30 years ago. The pressed metal planetary exploded putting a square or rectangle hole right through the case. The gasket and bolt area were not affected. I just trimmed the broken parts off the ground it neat and welded in a plate, lasted ten more years, and over 100k mi. Then it was sold off.

  • @TalRohan
    @TalRohan Рік тому +3

    Watching what you were doing to clean it up makes me think of that cheap low temp "welding rod stuff" that is advertised all over at the moment
    Shame about the outcome though, its not often something like that doesnt work for you, you did some truly impressive work on that casing.

  • @apd5084
    @apd5084 Рік тому +3

    damn surprised the repair didn't work. you made a great attempt... love your work

  • @freebirdwelds
    @freebirdwelds Рік тому +1

    I can only imagine how hot it got in your shop with the heater running. Kudos on the effort which I'm sure could be measured in sweat.

  • @bwinford1561
    @bwinford1561 Рік тому +1

    Wow! Give you credit for tackling this job. As to addressing the gap between the case i would have masked one side and jb weld the other side (gap), bolt together and let set.

  • @blackbuttecruizr
    @blackbuttecruizr Рік тому +11

    Nice fix, congratulations on the new gear!

  • @davidmonro3270
    @davidmonro3270 Рік тому

    You are just so sensitive to the metal and do such dainty work I think those like yourself deserve far more credit than you receive.

  • @georgeantonaros5580
    @georgeantonaros5580 10 місяців тому +1

    Good job Isaac for what you had to work with, they had absolutely cooked that cast aluminum before you ever received it, it is difficult to play second fiddle and come out on top !! 🤗

  • @stangaloski4208
    @stangaloski4208 Рік тому +2

    Hell of an attempt. I would have walked right off the bat. I commend your abilities!

  • @crabmansteve6844
    @crabmansteve6844 Рік тому +1

    Every time you grind away some porosity from the botched first repair you just get into more and more porosity. Wild.
    That first repair looks like it was done with a gas torch.

  • @carloskawasaki656
    @carloskawasaki656 Рік тому +2

    Thank you for sharing, i learn a lot, another great video,always a pleasure watch your video,have a nice week end 👍👍👍👍

  • @waynepollard6879
    @waynepollard6879 Рік тому +1

    It reminds me of a dentist , you and that grinder , in fact they could show this episode to dental students ! Thank you for the video as always !

  • @greggszyp7371
    @greggszyp7371 Рік тому +1

    I do appreciate all the effort you went through to make this video. Unfortunately for the customer I know they spent more than the cost of a used junk yard transfer case just in your labor to clean out the old welds, let alone your labor cost to weld it. A new case half from the dealer is only $3-400 last time I bought one.

  • @Dave_9547
    @Dave_9547 Рік тому +6

    That base with the grooves looks like a table off of a shaper, probably a pretty good sized one.

    • @ICWeld
      @ICWeld  Рік тому +8

      Big Radial arm drill

  • @FishFind3000
    @FishFind3000 Рік тому +28

    1:57 that gap also probably contributed to the failure since it could be over torqued there forcing it and causing stress till failure.

    • @AndyL940
      @AndyL940 Рік тому +12

      I think bouncing over a rock contributed to the failure 😂 The gap was a result of the first person’s attempt to fix it

    • @wirefeed3419
      @wirefeed3419 Рік тому

      Not at all, the case was damaged by whatever it first hit. The case was then ruined by whoever thought they were welding aluminum.
      Issac got close but ideally the case half would need to be surface planed or ground to get a seal surface again.
      Too much cost to make it worth while… replace the case

  • @danielpullum1907
    @danielpullum1907 Рік тому +3

    I am shocked. You reserved all that tedious die grinding for your personal viewing.... LOL Great work Isaac. Few folk would even attempt the job. The previous comment hit the crux of the problem. Alum castings look so nice until you try to weld them.. It is funny the crud doesn't seem to affect the casting quality.

  • @GutPyle
    @GutPyle Рік тому +1

    You're an artist, my friend. And I hope you got paid what you're worth for doing it. 👍

  • @mfc4591
    @mfc4591 Рік тому +1

    IC Weld to the rescue, well done. I would be very happy with that repair

  • @johnkizziah108
    @johnkizziah108 Рік тому +1

    That stuff is my fave to repair have been doin that kind of repairs for over 50 years. Lots of antique motorbike parts. Take alot of pride in my repairs. Cast aluminum is a different kind of repair.

  • @chrislindquist2003
    @chrislindquist2003 Рік тому +1

    Was waiting for you to upload a new video. Always enjoy watching you work Isaac.

  • @petermccuskey1832
    @petermccuskey1832 Рік тому +3

    Thank you for the content. Your schooling on the videos is fantastic.

  • @michaelweatherhead9470
    @michaelweatherhead9470 Рік тому +3

    Well done Issac very nice thanks for the video ❤❤ it. Take care of yourself and family and be Blessed ❤️.

  • @johnblecker4206
    @johnblecker4206 Рік тому +1

    I hit pole while doing wheelie and used some J-B epoxy to patch the cover to avoid trying to welding aluminium again.
    That cover has seen better days.

  • @isbcornbinder
    @isbcornbinder Рік тому +8

    That looks like an NVG 241 housing. There are thousands of them in recycling yards. I bought a low mileage one for $140.

  • @chadkennedy529
    @chadkennedy529 Рік тому +1

    Looks like it was done with a spool gun initially.... no Bueno 😂 fixing these type of castings in the best case scenario are really tough. Look good now👌

  • @garyharrington5300
    @garyharrington5300 Рік тому +1

    Tig and mr professional for the winn ,great job and awsome vidio!

  • @chotuusian4127
    @chotuusian4127 Рік тому +1

    Good work👍

  • @extracrazyguy
    @extracrazyguy Рік тому +2

    Metal magician!!
    You have amazing skill ....

  • @TheVespap200e
    @TheVespap200e Рік тому +1

    You win some,you lose some! You gave it your best shot. That's all that matters. I'm not sure what those cases cost but for the time you put into fixing it,I would think it would have been better for the customer to invest that money in a new one. Just my 2 cents! 😁👍

  • @bsteleven
    @bsteleven Рік тому +4

    Nothing ventured nothing gained! I’ve spent my entire life repairing machines of all sorts, No matter the outcome ya just got to keep on trucking. This job you took on wow what a mess to try and repair someone best try!

  • @mikehoefs2731
    @mikehoefs2731 Рік тому +1

    Can’t help it bud.. every person has a different perspective but not everyone has really done aluminum cast! Again it stinks and most times breaks in the hardest to weld places! Rims, boats, door frames are considered a clip excursion. Always easier to weld but create hydrogen when welded. Seen some X-rays of new welded and it’s a sponge! Believe me after 30 years of welding it it is what it is bud.. swiss cheese pard! I love how you take anything on just to try. Gets me in trouble all the time but love it when it works out! A heavy coat of black paint will work wonders on cast aluminum pin holes. Thanks for your time bud. Your patience alone is worth $

  • @jwaterous224
    @jwaterous224 Рік тому +1

    I think part of the problem is welding a cast work peice. Of course cast aluminum has pores that randomly appear after being remelted. Much respect because of the best effort possible! I guess IF you were set up to be a foundry a chunk could be cut out then modeled up then cast from aluminum and stuck in place.

  • @richardlincoln8438
    @richardlincoln8438 Рік тому +2

    Darn fine effort Issac. I think that You would have been successful if You had the first try at it. Thanks for sharing.

  • @jamesbruno5896
    @jamesbruno5896 Рік тому +3

    Amazing repair!

  • @alexcapuchinojr1288
    @alexcapuchinojr1288 Рік тому +3

    Great work welding on that aluminum

  • @binks166
    @binks166 Рік тому +1

    I enjoyed your video !

  • @itsverygreen532
    @itsverygreen532 Рік тому +1

    You did really well on that. If they had got it to you before the other guy had a go, I think you would have saved it. Sadly with the amount of distortion, that was never going to be easy. Nice work though, some you win ...

  • @chuckyc6912
    @chuckyc6912 Рік тому +1

    Always learn something from you. Great job

  • @Rx7man
    @Rx7man Рік тому +3

    Good try!.. Monday morning quarterback on what I'd have tried is to cut a thin slice near that bolt boss, clamp everything down tight, perhaps even with a thin feeler gauge under a couple of the neighboring bosses, weld everything else, then weld up my cut and hope it comes out close enough to straight to be able to sand it flush.
    definitely not easy to work the impurities out of that cast though and sure makes a decent weld on top much harder to do

  • @johnwesner3935
    @johnwesner3935 Рік тому +1

    Well, can't blame you for not working out. You may have been able to save the piece of you had first attempt. I've got an aluminum oil pan from my old Bobcat. 20 HP Kohler horz.twin. the starter mount snapped off. Sort of a weak looking affair. I was able to find a " marketplace" used replacement. If something happens to this one, I'll drive down from Wisconsin!:)

  • @mayhemmayo
    @mayhemmayo Рік тому +4

    KEEP UP THE GOOD WORK

  • @Asomesauc
    @Asomesauc Рік тому +1

    Great video thank you for sharing

  • @davidgalenbeck7616
    @davidgalenbeck7616 Рік тому +1

    Dude that is awesome

  • @mikehoefs2731
    @mikehoefs2731 Рік тому +4

    Just returning a favor bud.. I have done many repairs to aluminum casting. Transmission and transfer cases. If you have a old stove whether gas or electric it works great for preheating and boiling out the crap slowly! You can always throw it back in a couple of minutes. Two three times per side. Second you will never get all the porous welds clean! Its a nonferrous spounge. Set your cleaning action at max.. run your beeds cool slowly and even when you buf it down rarely will it leak with a few holes! Good luck pard! Ps the profax 1260 gun is awesome

  • @texascottonfarmer
    @texascottonfarmer Рік тому +1

    👍👍👌👌 Thanks for the video!

  • @richardellis3141
    @richardellis3141 Рік тому +1

    nice repair

  • @josephbok2295
    @josephbok2295 Рік тому +1

    Man you know how to pick them

  • @stevefrost3509
    @stevefrost3509 Рік тому +7

    Couldn’t they get another case ?love your work🇬🇧👍

    • @Failure_Is_An_Option
      @Failure_Is_An_Option Рік тому +4

      Yup. Most of them are stupid expensive.

    • @AndyL940
      @AndyL940 Рік тому +1

      Doubt that unless it’s rare . That’s not

    • @Rx7man
      @Rx7man Рік тому +5

      @@AndyL940 yeah, just looks like an NP241 or later variant

    • @ICWeld
      @ICWeld  Рік тому +4

      yup 241

  • @mrdddeeezzzweldor5039
    @mrdddeeezzzweldor5039 Рік тому +1

    My initial thought is it does not look like aluminum but alumiweld or similar 'repair' rod, especially when the thin piece on the inside was chiseled out. The bubbly outside look seems to say excessive heating with the torch because the casting had gotten oxidized and the alumiweld would not stick?

  • @tubeonline629
    @tubeonline629 Рік тому

    Oh NO, NO, NO Hey man that transfer case is Magnesium. You need magnesium filler rod. I ran into the same problem several years ago, had one that had a small hole worn into by the chain, I cleaned, stainless brushed and tig welded with 4043. Was putting my stuff up and heard a little pop sound , the filler metal popped up a little . Tapped it with my hammer and it popped out. I figured it out finally and ordered some magnesium filler rod. It worked

  • @scotthultin7769
    @scotthultin7769 Рік тому +4

    141👍's up IC WELD thank you for sharing

  • @petersmart1999
    @petersmart1999 Рік тому +1

    You gotta try some Plantex flap wheels with Kangaru oil! It removes material so fast and no gumming! A simple cleanup with acetone and away you go.

  • @Hey_Its_That_Guy
    @Hey_Its_That_Guy Рік тому +1

    Good thing you had to run your heater. Heard it's been mighty cold down there in Texas. 🤣

  • @wobbiewall4821
    @wobbiewall4821 Рік тому +1

    That's the "Attack of the Spool Gun".

  • @mrmongo6722
    @mrmongo6722 20 днів тому

    Even if it didn’t get used it was still an entertaining video. There is only so much you can do with JB Weld and a bubble gum weld somebody else attempted to use.

  • @truracer20
    @truracer20 Рік тому +1

    It looks like the previous repair attempt was done with a spool gun and no thought was given to keeping alignment, not just on the mating surface but of the bores.

  • @fgpriceinc
    @fgpriceinc Рік тому +1

    First guy ruined that thing. It was a valiant effort!

  • @GarnettM
    @GarnettM Рік тому +2

    It should work Isaac Thats a Ford Transfer case there's a gasket anyway Could silicone it too .

  • @RetiredPilot
    @RetiredPilot Рік тому +1

    I have fixed transmission cases with JB Weld if the crack /hole is not structural. They have lasted for years.

  • @philipsavickas4860
    @philipsavickas4860 Рік тому +1

    I have found if you use the gas ax to burn the oil out with the oxygen cutting lever depressed not trying to heat the part up gust burn oil off it works well to clean up cast aluminum

  • @somerandomguy3868
    @somerandomguy3868 Рік тому +1

    A difficult repair at best nevermind it's second go at being repaired, cast aluminum never welds well and there's no guarantee that it will be successful, still an excellent example of the challenges this type of repair offers

  • @halfabee
    @halfabee Рік тому +1

    With aluminium it is possible to heat it up so hard soap burns on its surface then quench it. This will remove all the work/age hardening the aluminium has received.
    Also during this heating process it will show up if there is any oil trapped in the aluminium as it bubbles out.

  • @James-fs4rn
    @James-fs4rn Рік тому +1

    👍if you can't fix it, it ain't broken

  • @roneckler9937
    @roneckler9937 Рік тому +8

    At first when you put that aluminum in front of the heater, I thought you would have tried to trick us into thinking it melted from getting to hot. lol It was a good effort in trying to fix it though.

  • @weldmachine
    @weldmachine 11 місяців тому +1

    Welding, Aluminium Crankcases, Gear Boxes etc can be a pain ???
    The primary work in my shop was previously Repairing Aluminium Casings.
    The jobs that look like would be a absolute pain actually went really well.
    Where as Cases that should be fairly straightforward were absolute Nightmare.
    Unfortunately, with some jobs I had to simply give up and hand the part back to the customer without completing the Repair ??
    It's not a great feeling to simply give up from the sake of failing ???
    But, some Cases were totally un-repairable no matter how much effort I put in.

  • @charlietanner6211
    @charlietanner6211 Рік тому +1

    the master of disaster at work that was a mess

  • @pgmpxk
    @pgmpxk Рік тому +3

    It will be interesting for us also ;)

  • @timtrax918artisan8
    @timtrax918artisan8 Рік тому +1

    I'm thinking the original repair was with one of those weld sticks and an propane torche you see at the the county fair booth. They probable have a use but not in this case.

  • @WorldPowerLabs
    @WorldPowerLabs Рік тому +3

    Did you ever get your Dynasty fixed, or are you still on an alternate machine? Just curious how extensive the problem was, if it's fixed.

    • @ICWeld
      @ICWeld  Рік тому +3

      Never got it fixed. Considered sending the circuit board to a friend who might be able to repair it. hadnt moved forward with that either. 😕😕😕

  • @russellgilson4072
    @russellgilson4072 Рік тому +1

    cast aluminum is tough to weld, it was completed with the best skill set!

  • @danburch9989
    @danburch9989 Рік тому +15

    The previous welder welds by the saying, "The bigger the glob, the better the job." Well, not in this case.

    • @d.jensen5153
      @d.jensen5153 Рік тому

      no pun intended

    • @johnkruton9708
      @johnkruton9708 Рік тому

      I’m a home gamer and I’m going to use that quote !!!😂🎉

  • @mrln247
    @mrln247 Рік тому +1

    Atleast it was an interesting learning experience.
    If it was me doing it would have just JB welded it feom the first break for a "cold" weld, if it holds oil keep trucking.
    The first job was a good example in epic porosity.

  • @MaverickandStuff
    @MaverickandStuff Рік тому +1

    Looked like they try fixing it with some of that low temp aluminium brazing rods.

  • @steevemachine118
    @steevemachine118 Рік тому +2

    Great work! I am still wondering why you're not using auto darkening helmet!

    • @ICWeld
      @ICWeld  Рік тому +2

      My hood does have an auto darkening lens. I use the flip hood version for the grinding shield aspect of it.

  • @09FLTRMM77
    @09FLTRMM77 Рік тому +1

    MM77 Approved 👍🏼👍🏼

  • @jbkbrand
    @jbkbrand Рік тому +2

    I agree. Should have been melted down. That said I have had “MINIMAL” success in the past by taking the support ribs from one side of the case and building matching ribs on the other side especially around the bolt holes. Then building up the low spots a filing them down as I went along. As I said minimal success. Good luck

  • @marriagepartnersministry5942
    @marriagepartnersministry5942 6 місяців тому

    Is there a certain temperature you need to get the casting to and maintain at while adding weld? How do you know if setting it in front of the heater is adequate or not or to hot?

  • @Daniel_cheems
    @Daniel_cheems Рік тому

    Hi Isaac! Excellent work considering the existing damage.
    if you weren't able to bend that housing back into alignment, would lapping the mating surface would have worked?

    • @ICWeld
      @ICWeld  Рік тому +1

      Great point, not sure

  • @breikowski
    @breikowski Рік тому +1

    Looks like aluminum mig weld, but the had it positive lead instead of negative feed. And not enough shielding gas.

  • @williamkelley7654
    @williamkelley7654 Рік тому +1

    A replacement case would be cheaper than your time although it's a common failure so maybe there's no stock anywhere? Either way your welds are certainly 10000% better so at least it has a chance.