After replacing my motor mounts, I decided I'd better take a look at the transmission mount as well. So today while I had the car (2002 996 Cab Manual trans) up on jack stands I'd remove the underbody covers and have a peek. To my horror a couple pieces of the transmission case that support the mount fell off the cover as I tilted it down. 2 chunks of aluminum have aparently broken off of the case itself so now the transmission (and entire front half of the drivetrIain) is just resting on the mount by gravity. Oddly enough, I didn't feel that anything was wrong the last months I've been driving it. Shifted fine, no clunking. I'm pretty sure it's been busted as long as I've owned it. It appears that someone had tried to repair it using JB Weld or something!

I guess I'm asking if it can be repaired by welding it back together (if that is even possible) or if that would be unreliable, can I buy a new case and transfer all the internals? Or should I look for a used transaxle somewhere? Obviously, I wand to do the right thing, but not spend more than I have to. Below are some photos of my ugly situation. Any constructive opinions of how to proceed would be much appreciated.

Bottom of Trans mount area

Evidence of glued repair

These are the pieces that have broken off

Front of the mount.

Exposed trans mount

 

Caveat: I am just an average DIY gear head . In my opinion your best bet is to find another case or transmission . Yes it could be tig welded but in my opinion would have to be welded inside and outside . Obviously any weld bead in the inside bore would have to be sanded/honed so a new mount bushing can be installed .

That really sucks that someone attempted such a poor repair . I am interested to see what others have to say . Good luck 🤞

 

Yes you need a new case at the minimum. Maybe the prior owner attempted to install a new trans mount and cracked the case while pressing in or out. Looks like they painted it silver to hide the evidence,

 

I would try to weld first. You can get a mobile welder to do if.

 

If you decide to replace your busted transmission I might be interested in buying the busted one depending on mileage and condition

 

2 broken pieces, pressed in bushing with rubber insert, in the car, aluminum, attached to the transmission?

 

Wow! That’s a pretty lame repair. I’d wager that someone tried to pound a new mount bushing in there and broke it. In the words of Forrest Gump, “stupid is as stupid does”…I’d think most good machine shops could weld (properly) and re-bore to original spec. The problem is, you’d have to drop the transmission and haul it to them… it probably weighs a good 300 lbs or so… 😬 ugh…

 

And that is why the last guy glued it back.

 

Like I said in my first post - Stupid is as Stupid does!

 

Trans is only 150-175lbs. I can move mine around by myself. I would have it welded and bored. Its gonna be signifcantly cheaper then buying a case and swapping internals. I decent machine shop should be under $300. If u r near me, Philly area, i got a guy.

 

That is an easy repair for any competent welder/machine shop that should be just as strong (if not stronger) than the original casting. A new transmission is $5000+ if you're lucky, this repair should only be a couple hundred dollars.