Help with 915 transmission case damage

[Dr J]

I had my axle come off at the cv joint. When I inspected for collateral damage, I saw that the case of the transmission suffered minor damage, but it dislodged a bolt that has a spring for a gear detent.

1) Any suggestions for repairing the case damage?
2) I moved the shift lever in the process of moving the car. Did I mess anything in the transmission given that the spring for the detent was part way out?

This is for a 79 SC with 915 tranny.

[rattlsnak]

ouch, it doesnt look like there is enough case there to insert a helicoil or timesert.. if thats the case, you're going to have replace the center section of the trans, or possibly take it somewhere and get it tig welded and then retapped.

[sc_rufctr]

That's the differential section! Not as easy to replace as the mid section because of the differentiate backlash settings.
.... You need a special ($$$) tool to re do the setting and a complete tear down.

Not a good situation but it could be worse. You may be able to get someone to build up the area by welding it and then re cutting a new thread.
Of course they have to know what they're doing otherwise you'll end up with alloy chips inside your gearbox.
With a bit of luck you'll find someone who can do it without pulling the gearbox from the car.

If it was mine?

Yank it out... Complete strip down and get the broken area welded and new thread cut. $200 max
Then take the opportunity to reassemble with some fresh synchros and sliders. $500-$600.

I really hope it works out OK. Good luck.

[Dr J]

Alright guys, thanks for the suggestions.

After reading the comments, I think the picture is a little misleading.

The left side of the boss is intact. Only a part of the right side came out. The insert is out because the bolt got whacked and deformed the insert as it pulled out on the broken side. Since I don't want to do a drop just yet, I am going to put a new helicoil, a new bolt, and build the area back up with JB Weld. At first I was concerned about temperature, but JB Weld is used in the engine case anyway so it should hold up.

Whenever it comes time to do a drop or I think the tranny needs refreshing, I'll have it rewelded.

[sc_rufctr]

JB Weld should work but I would definitely check it often.

[Dr J]

Taped it up and filled the missing part with JB Weld.



First put a helicoil in there and inserted a large bolt that was oiled. Then taped around.



After it dried, I sanded it and decided that in order to properly seal with the crush washer, I needed another metal surface so I JB Welded an appropriately-sized washer, reinstalled everything and we're back on the road for about 100 miles so far.

This was collateral damage from the original incident:



Thanks to gshiwota who had a free starter in California and sent it to me for the price of shipping. Replaced the case and was ready to go. This time, I was taking no chances, so after reading about different methods to secure the CV joints, I decided to go for the Nordlock washers out of McMaster-Carr.



Everything should be set for now.