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Old 03-16-2013, 03:16 PM   #1
codesoccer
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Default Hole in Transmission

So I'm driving home from work yesterday and hear a big clunk. I have no idea if it was road debris or something else. I start getting closer to my house and I'm smelling tranny fluid. I get under the car and find this hole . Can this be welded?

The car has a full 04 sti tranny swap.

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Old 03-16-2013, 04:51 PM   #2
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My brother is a welder and he says Yes. It can be welded. He has done repairs like this before on sport bike frames and engine blocks.
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Old 03-16-2013, 05:40 PM   #3
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You better take a look inside. That hole was punched from the inside.
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Old 03-16-2013, 05:43 PM   #4
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Quote:
Originally Posted by GDR View Post
You better take a look inside. That hole was punched from the inside.
+1 have a look inside before you kill the entire tranny.
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Old 03-16-2013, 05:57 PM   #5
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Quote:
Originally Posted by GDR View Post
You better take a look inside. That hole was punched from the inside.
While I know this is the internet and you can only speculate, any idea as to what could have done it? I drove the car for about 20 miles yesterday after this happened and it "seemed" fine. I have no idea if or not it caused damage.
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Old 03-16-2013, 07:09 PM   #6
GDR
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Originally Posted by codesoccer View Post
While I know this is the internet and you can only speculate, any idea as to what could have done it? I drove the car for about 20 miles yesterday after this happened and it "seemed" fine. I have no idea if or not it caused damage.

Just taking a wild guess by looking at assembly drawings. One of the retaining bolts came loose from the rear bearing and got shot or forced into the case by the transfer gear.Take a look in that hole and see if that's where the gear is.

Its still possible something hit it from the outside but from the shape of the hole fracture and location I highly doubt this. Either way you still need to pull the tail housing off to get it welded correctly.


I wouldn't keep driving the car even if things sound ok. You are still loosing oil. Problems from low oil don't show up right away.
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Old 03-16-2013, 07:14 PM   #7
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Quote:
Originally Posted by GDR View Post
Just taking a wild guess by looking at assembly drawings. One of the retaining bolts came loose from the rear bearing and got shot or forced into the case by the transfer gear.Take a look in that hole and see if that's where the gear is.

Its still possible something hit it from the outside but from the shape of the hole fracture and location I highly doubt this. Either way you still need to pull the tail housing off to get it welded correctly.


I wouldn't keep driving the car even if things sound ok. You are still loosing oil. Problems from low oil don't show up right away.
Thanks, I'm gonna try and get a closer look and see tomorrow. I'm definitely not driving it till this gets sorted out.
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Old 03-16-2013, 10:38 PM   #8
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Quote:
Originally Posted by GDR View Post
Just taking a wild guess by looking at assembly drawings. One of the retaining bolts came loose from the rear bearing and got shot or forced into the case by the transfer gear.Take a look in that hole and see if that's where the gear is.
.
So I took a look inside and I can see the gear. I'm pretty sure you were right. I'm guessing it's one of the two bolts I circled in the pic below.

I don't have any experience opening up a tranny but I did do my own tranny swap so I'm not mechanically challenged. If this is the problem, would repairing it be as easy as pulling the rear of the transmission off then replacing the bolt and having it welded?
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Old 03-17-2013, 05:42 AM   #9
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Study the FSM for the trans before doing anything. Just pulling and reinstalling the housing is not a big deal and you should be able to do it on the car.But if parts need replacing it can get complicated.
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Old 03-17-2013, 11:26 AM   #10
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Quote:
Originally Posted by GDR View Post
Study the FSM for the trans before doing anything. Just pulling and reinstalling the housing is not a big deal and you should be able to do it on the car.But if parts need replacing it can get complicated.
+1 good knowledge is the best advantage you have in this situation, read the FSM.. If your feeling confident pull the housing and take a look. Post some pics of your findings. Maybe someone can steer you in the direction you need to go from there.
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Old 03-17-2013, 12:15 PM   #11
codesoccer
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Quote:
Originally Posted by GDR View Post
Study the FSM for the trans before doing anything. Just pulling and reinstalling the housing is not a big deal and you should be able to do it on the car.But if parts need replacing it can get complicated.
Quote:
Originally Posted by EJ20cosworth View Post

+1 good knowledge is the best advantage you have in this situation, read the FSM.. If your feeling confident pull the housing and take a look. Post some pics of your findings. Maybe someone can steer you in the direction you need to go from there.
Thanks for all the help guys. I'm gonna look over the FSM tonight and tackle it tomorrow. Ill post pics of my findings.
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