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Old 06-09-2008, 06:31 PM   #1 (permalink)
bhsmedley
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Cracked rear housing... what next?

Noticed a trans fluid leak the other day after some looking around found a small crack in what I though was just a spacer plate. After 2 tubes of JB weld and a roll of liquid steel it still leaked. Took the transfer case off and saw a crack around the entire inside of the trans housing. After taking the bolts out of the rear of the trans and a little prying I noticed the rear shaft wasn't moving looked inside and seen the little clutch springs and it doesn't want to slide back together.
Any ideas where I can find a new rear housing and how to get it back together, I used to simple old TH350s and this has got me a little nervous and I'm sure Suncoast doesn't warranty again casing cracks
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Old 06-09-2008, 07:04 PM   #2 (permalink)
trentnell
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if it is the extension housing you have to get it from gm, i f it was me i would pull the tranny to do the repair, you might be able to do it with it in the truck but there are alot of partsb thatcould come out with the extension housing of and there is a spac`er that you need to make sure stays aligned , get an atsg manual, you can download for 20 bucks at atsg.com, and it will make more sense, if it is the extension housing that is cracked its about 500 bucks from gm , is it a built tranny or stock, and the spacer i mentioned if not aligned properly during install might be able to crack the extension housing from being forced together and ran ? good luck to ya , hope this info helps.
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Old 06-09-2008, 07:42 PM   #3 (permalink)
trentnell
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see page 108 of atsg manual for the sun gear spacer goes in after the main shaft and p2 sun gear i think the springs you saw are the c5 return springs . if the spacer was bound up during install you should see some damadge to the splines on the inside of the spacer
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Old 06-09-2008, 08:20 PM   #4 (permalink)
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you can get the rear extension housing from Suncoast too. They even make a billet rear extension housing, but its pricey. You can also do it with the trans in the truck, I did it, it was actuall kinda easy. But, you do have to be cautious as the rear clutches and steels will come flying out on you, as will the parking pawl and a few other small pieces. As long as you know how everything goes back in, your fine. I did mine in a few hours.
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Old 06-09-2008, 10:03 PM   #5 (permalink)
modified
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Suncoast claims driveline vibration, like from worn U-joints can cause the rear housing to crack, that's why they sell the T-case bracket. Because of the way the T-case is only supported by the transmission, about 80 lbs is hanging off the trans extension.
Allison redesigned the rear extension housing with more or larger gussets because of this problem.
You can order the parts from Merchant:
http://www.merchant-automotive.com/a...ousing4x4.aspx
http://www.merchant-automotive.com/s...casebrace.aspx

Don't forget to check/replace your U-Joints.
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Old 06-09-2008, 10:34 PM   #6 (permalink)
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pm me if you want i know a place to get genuine allison parts for a third what you can buy them anywhere else.
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Old 06-09-2008, 10:41 PM   #7 (permalink)
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pm me if you want i know a place to get genuine allison parts for a third what you can buy them anywhere else.
So you can get me Allison spin on filters for 2.50, NSBU switches for 18.00, deep pans for 20.00? I can gaurantee you a minimum 100,000.00 order within the hour.
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Old 06-09-2008, 10:55 PM   #8 (permalink)
bhsmedley
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All the u-joints are good but the fields have been muddy around here and I had some clay packed in the duals and haven't driving it that much, surely that wouldn't be enough of a vibe to split that housing all the way around would it?
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Old 06-10-2008, 12:35 AM   #9 (permalink)
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mine cracked due to a severly worn u-joint and a bad vibration that I couldnt find. The vibration turned out to be the bad u joint that I somehow missed. Oh yeah, and mine cracked with the transfer case bracket installed.
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Old 06-10-2008, 09:58 AM   #10 (permalink)
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Oh yeah, and mine cracked with the transfer case bracket installed.


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