expensive gear oil change...need new GB!

[hunty]

So i thought it was about time i changed over my gearbox oil, no idea when it was changed last as the previous owner didnt have any service history that mentioned it being changed, so i did a little reading on here and thought i'd give the redline mt90 a whirl, so i had a little trouble undoing the filler bolt, but a little penetrine spray and a breaker bar and some small taps with a rubber mallet and she was off good as gold, same with the drain plug. So far all is going well. i finish up refilling the gearbox with the last bottle of mt90, needed 4 of em at something like $28AUD each. now time to put the filler bolt back, tightening it back up with my socket wrench which is only a stubby like 6 inches long so not a lot of leverage can be made but i was just tightening it up so it wouldnt leak and just as im tightening it up SNAP, the bolt breaks off the flange on the gearbox in two pieces! heres a picture to show you what i mean.



i suspect that its just metal fatigue as i did not put the sort of strain on it that would break it off like that at least i didnt think so.

so am i right in thinking i've completely rooted the gearbox and i better go out hunting for one??


cheers,

[love ke70]

should be repairable
what gbox is it?
but cast metal can be welded apparently, or im sure there will be a product that will cement that back in place....

[Sagluren]

now that sucks. you might be able to find a new casing and transplant all internals if you wanted the hassel.

sam.

[Dale]

You won't need a whole new box, just that rear casing.. provided you can find one
Find someone with a stuffed box they want to get rid of and do a swaperoo

[Cuzzo]

Depending on box it could very well be easier for new box. Thats a good effort snapping it off. Good luck with your searching.

[Dale]

I get the feeling an e153 box won't be the easiest (or cheapest) thing to come by.. is the rear housing different to other e series boxes? If they are it would be easy to get another rear casing for it, but I think they're different.

Do they have equal length driveshafts? A gt4 box might share the same rear casing

[MWP]

Weld the hole up completley and tap a new one in somewhere else on the casing.
Its only the filler hole, doesnt have to be a brilliant seal.

Or if its a gbox like the W5x's, just take out the shifter and fill it through there.

[gianttomato]

Weld bit of broken box back on. Tap the thread. File the sealing surface flat. Use copper washer to help with sealing. Get on with life.

[hunty]

sorry forgot to mention the car/gearbox, as dale picked up its the e153 from a SW20 mr2 turbo. prices last time i looked were around the 2k mark

the casing looks to be an alloy/aluminium type thing so im not sure how well it could be welded up? definately not a home repair job, i'm ringing around different workshops today to try to find someone that might be able to help.

whats peoples thoughts on using something like JB weld? would that bolt be under pressure when the gearbox is going full tilt? dont want it to pop out and empty the box of oil when im giving it a hard time at 6000 odd rpm!


cheers for all the replies

[Norbie]

No, there is not any pressure inside a manual gearbox. The plug is just there to stop the oil falling out.

[thechuckster]

JB weld is good stuff - as is Dev Con - just ask Sean.

[ViPeR_NiPPleX]

shouldnt have a problem with welding it, just depends if you gonna yank the box out or not Honda boys use JB weld to hold turbo drain bungs in sumps, so it can't be too bad either.

[hunty]

well the welders i talked to are all too bloody professional, ohh no we cant weld it up with out the gearbox coming out of the car so the join can be cleaned and ensure a good join blah blah blah lol so ill give the jb weld a shot and if it dont work well it'l have to come out anyway

Cheers guys ill be sure and post back with pics of the ghetto repair job

[Tom86]

I had similar thing happened to me when I used to drive a Mini I broke a chunk off sump plug hole on the stupid speed bump .

I use that Dev Con stuff from repco to patch it up. It been fine ever since. If it can fix the oil sump on my Mini I'm sure you can use it on your gearbox.

[hunty]

i've given it a nice coating with some of that epoxy goop and heres the results, i'm still waiting for it to cure, but the idea will be that once its cured im going to sand/file that flange so its smooth and then use a piece of steel about the size of a 20c piece and then epoxy that over the hole and seal it all up with more epoxy, then a bit of hi temp spray paint and she'll be good as new

thanks for all the help and replies guys






GHETTO FABULOUS...infact i may just use a 20c piece lol