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I’ve just replaced the trans filter on my 2005 Jeep Liberty. The last time the trans pan was off was two years ago, when a local reputable trans shop rebuilt the trans following an overheat.
I discovered that the shop must have overtorqued one of the trans pan bolts, because there’s a crack in the aluminum trans casing right across one of the bolt holes. I didn’t take a photo, but the image below shows the location of the crack in red. That whole little chunk of the casing wobbles, and I think it’s only the RTV (in blue) that’s stopping it just falling out. The RTV has also done a perfect job of stopping it from leaking – there hasn’t been a drop out of it.
I’ve bolted the pan back up, and of course that bolt won’t tighten. I’ve just got my fingers crossed that the new RTV, in conjunction with the rest of the bolts, will seal it as well as the previous stuff did.
If, having disturbed it, it *does* now leak, what are my options? I’m assuming they’re very limited, but is there any hope of welding that chunk of the casing back into place? Heck, could a strong epoxy even do the job of holding it together? Or am I going to be facing replacing the trans?
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I believe you did the only thing you can do in a situation like that. Keep an eye on it but I think you should be fine.
If you find that the area begins to leak you can repair the cracked case with JB weld . you may end up having to use a heli coil insert to repair the bolt hole but this can be done. with the proper surface prep and allowing the epoxy to properly cure you can get an incredibly strong repair.
It’s been a few days now, with multiple heating/cooling cycles, and no leaks yet. I may have just dodged a bullet on this one…
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