Metal Epoxy Repair for Busted Transmission Case?!?!? Project Brutus, Episode 13

In this episode, I use Alum Bond metal epoxy to repair the busted transmission extension housing/tail housing for the ZF-5 4x4 transmission for Project Brutus. These ZF5 4WD extension housings are often cracked, and un-cracked ones are hard to find and EXPENSIVE, so I really need this repair to work!!! If you enjoy the video, please hit the LIKE button and consider subscribing to the channel! Thanks! Scott

[@donolbers]

A refugee from the HAMB here, and another vote for some support for the transfer case to take some weight off the tailshaft housing/transfer case adapter thingamabob. My '84 has done the same thing, and I am running out of extras, so a support for me it is 😉

[@THEBULLETPROOFGARAGE]

Hi Don - I do plan to do this, but there are a few ways to accomplish it. First would just be a simple crossmember for the transfer case. You'd have to figure out how to mount it to the TC, but that wouldn't be too difficult. The other option is to fab a brace that takes some of the stress off the extension housing. Lots of Duramax folks buy an aftermarket brace to help their transmission extension housings but no such animal for Fords so building your own is pretty much your only option. Thanks for the comment! Scott

[@MichaelJordan-jv6ic]

Yeah - that was a bit surprising when you drilled it out to see how thin the material is. I hope it holds for you. The addition of the bolts I think was a good idea. Looking forward to seeing more content!

[@THEBULLETPROOFGARAGE]

Michael - I was quite surprised to see how thin it was, too! I think the bolts should help, but time will tell. Thanks for the comment, and more content is on the way! Scott

[@2DE808]

Thanks for showing this, I need to look at mine now. I would think that the alumibond might be a little softer compared to the host aluminum, allowing it to flex slightly without breaking. Just thinking the alumibond might be less brittle, and now the area is more than twice as thick.

[@THEBULLETPROOFGARAGE]

That's what I'm thinking, too, Chris. Thanks for the comment. Scott

[@caleblee4856]

I hope this repair last as long as the motor! Great videos. Happy new year Scott!

[@THEBULLETPROOFGARAGE]

Caleb - I sure hope so, but it does make me nervous! Happy New Year, Scott

[@ydocproductions5593]

Fantastic work as always Scott! You had to use the tools and techniques you had on hand and I agree it’ll work just fine. The bolts were a good addition, and with the amount you used it’s impossible for that thing to leak ever again lol. I personally believe the 7.3 IDI motor you will be bolting this to will never produce enough torque to break the alumiweld. If this is a common place for these cases to crack then after fixing the problem it should be good to go for the life of the truck theoretically speaking. Looking forward to the next video😀👍

[@THEBULLETPROOFGARAGE]

Hey YDOC - thanks for taking the time to provide detailed feedback! I really appreciate it. If I do end up using this extension housing, I think I will fashion a brace for it. More to follow on that. Thanks again! Scott

[@mrbreeze5556]

Scott, Lisle Tap Sockets will help when tapping holes where the t handle won’t fit! They are GJ recommended. Great video as always! Happy New Year to you!

[@THEBULLETPROOFGARAGE]

Mr Breeze - Excellent! An excuse to buy more tools!!! Thanks! Scott

[@simpleman4224]

Hope that works out for ya! Happy new year! 👍👍👍👍🇺🇸🇺🇸🇺🇸🇺🇸🙏🙏🙏🙏

[@THEBULLETPROOFGARAGE]

Gonna have to cross my fingers on this one, Simple Man! Happy New Year!!! Scott

[@rockharvey5787]

Those 4x4 zf5s seem to crack often because the weight of the transfer case is hanging off the back unsupported. I see this one has been welded already in the place that they usually crack. I wonder if the crack you repaired is leftover damage from that first crack. If I were you I would make some sort of support for the transfer case to give your repair the best chance.

[@THEBULLETPROOFGARAGE]

I found the first crack after I disassembled the trans for a rebuild. When I took it in to a local shop to have the crack TIG welded, it got cracked again in the same area, likely happened when they welded it or when it cooled. I think I can make a support for the TC. Thanks, Scott

[@mattg7952]

Mine is cracked in the same exact place. I honestly wouldn’t have high hopes for a weld to hold nor does my buddy who does repairs for a living. Key repair is find a f super duty 2wd trans tail housing that’s never had a t-case hanging off it. I can only assume the crack is a byproduct of torque. Previous experience with an SM 465/NP 205 cast iron adapter that broke due to worn out mount bushings. Do the math 70’s vehicles with broken/worn parts in the 90s now 90’s vehicles with “ in the 2020’s.

[@THEBULLETPROOFGARAGE]

Matt - I'm thinking about fabricating a brace for it -- it would extend from the trans to the transfer case and bolt on to both. There's a company that makes these but not for ZF'5/1356 transmissions. A crossmember supporting the transfer case would also help. Thanks for the input! Scott

[@THEBULLETPROOFGARAGE]

Matt - forgot one thing - I can't run an S42 tail housing on my S47 trans, and I don't know if Ford was still producing the F Super Duty when the S47 trans came out. Will have to check. Thanks, Scott

[@mattg7952]

@@THEBULLETPROOFGARAGE You know GM used a torque rod from the factory to support the NP208. So everything twisted in the same plane. Come up with something similar and it’d probably help

[@THEBULLETPROOFGARAGE]

@@mattg7952 Yep. Going to see what I can figure out. Thanks again, Scott

[@juliuspekar7620]

I thought mixing that kind of stuff should be done in plastic container?

[@THEBULLETPROOFGARAGE]

I don't think it really matters as long as it's a clean surface.

[@Unloved_truly]

Any updates on the fix. Bout to have to fashion something similar on my f-250

[@THEBULLETPROOFGARAGE]

I ended up sourcing an uncracked one and sold this one. I'm not sure if it held up or not. Thanks, Scott

[@Unloved_truly]

@@THEBULLETPROOFGARAGE dang. Alright. Thank you.

[@DependableAutoTruck]

should work as long as the case doesn't flex

[@THEBULLETPROOFGARAGE]

Thanks for the vote of confidence! If I use it, I may add a brace of some sort. Scott

[@fishnfreak04]

Casually just uses grill to mix the goop in lmfao

[@THEBULLETPROOFGARAGE]

Hey, it makes a nice workbench!

[@kareemfrith837]

You just gonna mix on the nearest surface right?

[@THEBULLETPROOFGARAGE]

Yep!

[@robertleese5039]

Did it work

[@THEBULLETPROOFGARAGE]

Robert - I ended up sourcing an uncracked one; video pending. I'll probably sell this one. Scott

[@MrAnton0628]

can work alumbond 90935? to put on the outside in a crack of a ford transmission

[@THEBULLETPROOFGARAGE]

If it's an aluminum case, it's worth a try, but I would make sure it's very clean and oil free before applying it.

[@MrAnton0628]

@@THEBULLETPROOFGARAGE thank you

[@THEBULLETPROOFGARAGE]

@@MrAnton0628 Happy to help!

[@charlieboy501]

Hope the epoxy don't get into the fluid

[@THEBULLETPROOFGARAGE]

The epoxy is actually designed to be used in these type of environments. Thanks