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cracked tcase again!
https://auszookers.com/forum/viewtopic.php?f=5&t=5727		 Page 1 of 1
Author:  brendan [ Mon Jul 27, 2009 9:25 pm ]
Post subject:  cracked tcase again!
this is fucking bullshit. just got the a new/used case put on and its fucken cracked alread! i have a roctoy ring on it and the bitch desided it will still crack this time at the driver side mount.

havent even been offroad with it yet and only noticed it today when i saw a patch of oil under my car but i would say it happned today. i dont think ive even driven it hard today. ive just got a trac bar on so many it is be going harder because i can.

got a 1.6efi, 6.1 gears,lock rite, 32 bfs

because sierra cases are getting harder to find i am thinking of maybe fixing this one up. clean the area of the crack, grind about 3mm out of it and weld it back up?
just looked last time i cracked the case was on a different half. ive got a half thats alright doent show any cracks from the outside but ont he inside looks a bit suss
EDIT-just thinking now maybe the roc toy ring doesnt have enough gussest?

think this is the right end where it cracked

Image


Image
Author:  11_evl [ Mon Jul 27, 2009 10:45 pm ]
Post subject:  Re: cracked tcase again!
show us a better pic of your rock ring setup.

i have just put mine in and i dont have any of the bracing at the top mount like what you have in the first pic
Author:  brendan [ Mon Jul 27, 2009 11:16 pm ]
Post subject:  Re: cracked tcase again!
i dont have any of that end. but basicly its just notched into it with no guesset or anything.

what do you think the best way to fix it is? just weld it up? or replace with the other spare half i have which looks a bit sus on the inside.
hopfully i can fit it in thsi weekend got heaps to do

going out on the piss friday, wont wake up till at least 12 saturday then i got to do the rear brakes and bearings and fix tcase now :evil:
Author:  Brett [ Tue Jul 28, 2009 12:49 am ]
Post subject:  Re: cracked tcase again!
i'd be looking if some thing around the case is bent or broken to break both cases...
Author:  brendan [ Tue Jul 28, 2009 12:51 am ]
Post subject:  Re: cracked tcase again!
the 2nd case i am not sure if the crack was there befor or after the rocring was installed. it was however cracked right under the inout shaft
Author:  joeblow [ Tue Jul 28, 2009 12:52 am ]
Post subject:  Re: cracked tcase again!
when things are made too rigid the force has to be transfered somewhere. in this case it looks as if the aluminium is taking the stress.
Author:  brendan [ Tue Jul 28, 2009 2:01 am ]
Post subject:  Re: cracked tcase again!
joeblow wrote:
when things are made too rigid the force has to be transfered somewhere. in this case it looks as if the aluminium is taking the stress.
Any ider on how I could prevent this from happening again? Also what would you suggest I do to fix the crack? Would it be posible to reinforce that area?
Author:  joeblow [ Tue Jul 28, 2009 2:26 am ]
Post subject:  Re: cracked tcase again!
find a good shop that does proper tig welding of cast components and they should be able to add some more strength.
Author:  brendan [ Tue Jul 28, 2009 2:43 am ]
Post subject:  Re: cracked tcase again!
I am able to tig weld aluminium, I suppse it won't hurt trying will it? Just if it doesn't work Ill have to pull it out again. I just want to beef it up so it won't crack again. I'm thinking of building the area up with weld?
Author:  joeblow [ Tue Jul 28, 2009 2:44 am ]
Post subject:  Re: cracked tcase again!
tigging jap cast can be tricky, if you dont use the right gear it will become porous and make it worse.
Author:  brendan [ Tue Jul 28, 2009 2:53 am ]
Post subject:  Re: cracked tcase again!
yes, you got a point. but i might take that risk. do you think i should build up the area?

just doing some more thinking. thinking about building the area up and then putting some feropree around the area in a bid to strengthen it.

feropree is basicly a 2part epoxy sort of thing
Author:  joeblow [ Tue Jul 28, 2009 3:14 am ]
Post subject:  Re: cracked tcase again!
don't just build up the weld add material if possible. and make sure its welding grade aluminium, not just machining grade.
Author:  brendan [ Tue Jul 28, 2009 3:16 am ]
Post subject:  Re: cracked tcase again!
joeblow wrote:
don't just build up the weld add material if possible. and make sure its welding grade aluminium, not just machining grade.


got any sugestionly on adding material?

i will be tig welding it with a 5356 rod
Produces intermediate deposit strength, good ductility and corrosion resistance for welding of range of 3XXX, 5XXX, 6XX and 5XX aluminium alloys
• Suitable for gas welding and gas tungsten arc (TIG) welding
• Aluminium - 5% magnesium alloy rod

its the only rods i have. though i might look into buying some 4043 which is recomened for cast repair
Author:  joeblow [ Tue Jul 28, 2009 2:04 pm ]
Post subject:  Re: cracked tcase again!
weld the crack up then see if you can put some sort of gusseting on it.
Author:  zuki [ Tue Jul 28, 2009 3:03 pm ]
Post subject:  Re: cracked tcase again!
brendan wrote:
joeblow wrote:
when things are made too rigid the force has to be transfered somewhere. in this case it looks as if the aluminium is taking the stress.
Any ider on how I could prevent this from happening again? Also what would you suggest I do to fix the crack? Would it be posible to reinforce that area?


I have ordered one of these, hopefully this will stop cases from cracking/breaking/smashing
Image


David
Author:  shep [ Tue Jul 28, 2009 4:01 pm ]
Post subject:  Re: cracked tcase again!
zuki wrote:
brendan wrote:
joeblow wrote:
when things are made too rigid the force has to be transfered somewhere. in this case it looks as if the aluminium is taking the stress.
Any ider on how I could prevent this from happening again? Also what would you suggest I do to fix the crack? Would it be posible to reinforce that area?


I have ordered one of these, hopefully this will stop cases from cracking/breaking/smashing
Image


David


that looks great where did you find it? where can i get one?
Author:  zuki [ Tue Jul 28, 2009 5:13 pm ]
Post subject:  Re: cracked tcase again!
shep wrote:
zuki wrote:
brendan wrote:
joeblow wrote:
when things are made too rigid the force has to be transfered somewhere. in this case it looks as if the aluminium is taking the stress.
Any ider on how I could prevent this from happening again? Also what would you suggest I do to fix the crack? Would it be posible to reinforce that area?


I have ordered one of these, hopefully this will stop cases from cracking/breaking/smashing
Image


David


that looks great where did you find it? where can i get one?


Shep,
www.zuksoffroad.net make them but they are expensive as to surface post them, like postage is nearly the same price as the item themselves.
it is called the SNATCH, top name I might add.
David
Author:  shep [ Tue Jul 28, 2009 5:22 pm ]
Post subject:  Re: cracked tcase again!
i am tempted to reinforce my mounts however i like having a relatively
cheap part as the weakest link. i keep a couple of mounts in my glovebox and it is only 5 min to change.
Author:  jdk81 [ Tue Jul 28, 2009 6:02 pm ]
Post subject:  Re: cracked tcase again!
shep wrote:
i am tempted to reinforce my mounts however i like having a relatively
cheap part as the weakest link. i keep a couple of mounts in my glovebox and it is only 5 min to change.


+1 common sense in all it's glory.

I would like a case to protect the transfer etc from impacts, however I would rather keep the cheap mounts as hopefull they will be the first to break before the casing.
Author:  MART [ Tue Jul 28, 2009 7:55 pm ]
Post subject:  Re: cracked tcase again!
Get some more pics , I broke 3 cases , show us your mounts , its could be twisting when torqued , the rock ring needs pretty strong mounts to make it effective , you need to remove the urge of the transfer twisting , Cheers Paul.
Author:  brendan [ Wed Jul 29, 2009 9:56 pm ]
Post subject:  Re: cracked tcase again!
NOTE-i added in the guesset you see there going from the roctoy ring to the angle today

Image

Image


Image
Author:  brendan [ Wed Jul 29, 2009 10:04 pm ]
Post subject:  Re: cracked tcase again!
its all backtogether ready to be droped in. going to put it in tomrow so hopfully i get some sugestions on how to make it not crack again
Author:  Gwagensteve [ Wed Jul 29, 2009 10:11 pm ]
Post subject:  Re: cracked tcase again!
I didn't realise you still have stock rubber mounts. There's something terribly wrong if you are breaking cases with stock rubbers and a rocktoy ring. I haven't seen a case break on a car with stock mounts before.

I've seen stock rubbers stretch literally inches.

My guess is that there's some (or a lot) of misalignment in the mounts and you are springing the mounts/ring down onto the alloy case, which is loading it up. Pay careful attention to how snug everything sits before you start bolting it up.

Steve.
Author:  brendan [ Wed Jul 29, 2009 10:27 pm ]
Post subject:  Re: cracked tcase again!
so you mean make sure the mounts are in there aliment hole?
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