Tig welder needed to fix front cover on 99' F-250

[ozzy702]

My buddy Rich's F-250 powerstroke has a cracked front cover. The crack is about an inch long and very thin. It's currently wheeping oil from the crack. You have to pull the motor or cut out the crossmember to pull the drain pan and remove the front cover. Rich wants to avoid doing that at all cost. The cover is very thin (thus why they crack) so I'm not sure how difficult it would be to tig but figured I'd post up and see if anyone has ideas. Rich is willing to pay good money for a few minutes worth of work if someone can professionally fix it for him.

Thanks!

 

[spencurai]

I would JB weld that sucker...that stuff is amazing and cheap. Scuff up the aluminum with some rough grit sandpaper...maybe scotchbrite and lay on some JB weld.

 

[ozzy702]

I would JB weld that sucker...that stuff is amazing and cheap. Scuff up the aluminum with some rough grit sandpaper...maybe scotchbrite and lay on some JB weld.

We've debated going the JB weld route but want it to be long lasting and not create more problems down the road. The truck has fairly low miles on it for a diesel and has a LOT of life left so I'd hate to have the JB weld come off and create issues internally. Any reason I should worry about that? I don't have a ton of experience with JB weld but when I have used it, I've noticed is sticks very well.

 

[spencurai]

What is inside this housing(fluid, pressure)? I can't tell what it is?

Do your research on how to best get the JB weld to bond with the metal. It is pretty amazing stuff. I used it on an aluminum transfer case (exterior) and it held for over a year before the t-case grenaded of its own device.

 

[MikeGyver]

I'll weld it if you can take the part off and it can be welded from the outside. I don't have a bore torch that will get it from the inside, not that I'd want to try that anyways. If your wanting to keep the job easy and not remove the part then I'd say just JB weld it.

Aluminum castings being quite pourous, can be a PITA to weld because they absorb whatever fluid they come in contact with. TIG welding requires everything to be clean, so the weld area has to be cooked to outgas all the sh|t. Even with a new casting the part may require several passes to blend everything in depending on the alloy and quality... so unlike if it were clean steel, it's going to be more than a 10 minute job. If you can hardly get a camera in there to take a picture then trying to weld it (with all it's special considerations) could really suck if it's even doable.

Here's some pics of my past work: www.UtahWeld.com

 

[ozzy702]

I believe inside pressure is in the 60psi range. The problem is to take off the front cover it requires simply too much work and if we put that much work in we'd just buy a new front cover for it. How long/well does JB weld hold up to oil and shaking? Any other options other than JB weld.

Thanks for the response MikeGyver, sounds like welding may be tricky or not possible.

 

[Unimog]

JBWeld will hold up no problem to the oil. Strength is pretty good - especially if you grind down a little and give it something rough to bond to, and clean it up good. The question I would pose is what caused it to crack and do you think it cracked just due to defective part?

 

[ozzy702]

JBWeld will hold up no problem to the oil. Strength is pretty good - especially if you grind down a little and give it something rough to bond to, and clean it up good. The question I would pose is what caused it to crack and do you think it cracked just due to defective part?

Ford changed the housings. If you put the gasket for the new cover on the old cover it cracks the cover but if you put the old gasket on the new cover you're fine. It's a TERRIBLE design from ford. Rich didn't know a change had been made, used the gasket he was sold and then put it on and it ended up cracking the cover.