gouge in output seal on tranny
 

someone put a big gouge in the case where the seal goes on my tranny for my BMW 325. the PO tried to fix it with what looks like JB weld. i dont know if it was leaking since i just bought the tranny ($200).

any ideas? should i try to fill it with JB weld again? i thought maybe put some JB weld on it, then try to sand it down, then is there anything else i could put on it to help seal it when i put the new seal back in?

Not cheap, but it works: DOW 730 SOLVENT RESISTANT SEALANT from Aircraft Spruce

NOTE CHEAP?? wow! you aint kiding. what about when you have to replace the seal again? will it ever come out? i am having to clean off remains of the last seal.

I guess the "correct" fix would be maching the seal area to a larger diameter and using an oversize seal. I would expect that JB weld could work, as long as the area is very clean.

well, i thought about pulling the case end off my old tranny, but so far it only comes off about 1/8 of an inch. i have heard they have to be heated(?) to get them off and back on.
is there anything else i can put on the seal that will help with small scratches?

Not sure what the 325 case is made of, but if it is aluminum just have it welded... then sand it down to original... I had purchased a 280Z back in the day where the PO had just ran straight water for coolant... This had pitted the head so bad that it blew the head gasket.. took it in to the welding shop and about 100 spot welds and $160. later had all of the pits repaired and the head resurfaced...

Hylomar or some other similar sealant might work.

Sleeve it.

How big is the gouge? Can you take a good photo and post?

take the old seal cut it into 1/3rds use one of these to act as a form .

Clean the gouge out with acetone, a few times.

Scuff the gouge with some fine grit paper,
clean the area again test fit the seal make sure its able to fit over the gouge so the surrounding area is flush.

Get the JB weld and fill the gouge put a thin coat of grease on the seal, fix it over the JB, let it cure for 12 Hrs then remove the seal form.

Let the JB fully cure then sand the edges down,
use a small dab of Hondabond on the JB area and the new seal edge,
let cure for 24 before filling with oil

That will work... Excellent! :D