how to fix magnesium ??

[Dirtrag2]

Hey guy's,

we have a Chevy Duramax truck at the shop and it has developped a pin hole in the rear transfer case housing. ( either manufacture problem or corrosion related )  anywho it's $1300 to replace part with new one or $950 for a used one 

it's a magnesium casting so welding is out of the question but seeing as there is little to no pressure inside the transfer case, i wonder if we could just JB-Weld or something?

any suggestions?

thanks

[truckinwagen]

I would drill and tap for a small pipe plug, but thats just me...

-Owen

[theman53]

Drill, tap, and pipe plug??? tell the customer it is that OR $$$$$

[the caveman]

It could be welded. Gene Berg used to sell mag plate to reinforce air cooled beetle transaxles. However find someone to do it. JB weld will work, just make sure it's real dry before applying. Last one i did was a Audi TT 6 speed.

[Rabbit on Roids]

magnesium has to be welded in an alternate atmosphere doesnt it? (like in a container with absolutely no oxygen?)

and this must be a pretty common problem on these ally transmissions.. 2nd one ive seen this year.

[OM617]

JB weld.

[trev]

TIG welder will make quick work of it.

The TIG process was developed for welding magnesium. Before that, it was being welded with oxy-acet, and too much oxygen was burning parts needed for the war effort.

So welding isn't really out of the question, unless the combined shop hours and welders fee's add up to more than the part will cost outright.

If the drill and tap routine will work, I'd go that way. Add another pipe thread type 'drain plug' to the casing, and carry on. If it's a pinhole from a casting flaw, it'll work out fine, if it's from corrosion, the drilling will certainly show that it's worse under the surface, and has to be dealt with anyways.

Most basic tap and die kits have 1/8 Pipe and 1/4 Pipe thread taps in them. Cheap and available.

Use a little Loctite on the plug, and yer in!

Cheers
  Trev