Dodge 3rd gen transmission drip drip drip

[Bigstar]

Yes I posted on the Cummins forum but you guys are usually much more responsive.

I was getting ready to take a long trip in my 2007 5.9 automatic to pick up a 12 valve manual truck I’ve been wanting for awhile.. 1200 miles with a hauler on the back. Before my trip I changed my oil, checked ALL the fluids and greased ALL the fittings. My trans fluid was about a quart low and when I climbed under the truck with a flashlight there were drops of trans fluid on the pan and transfer case as well as coating the underside of the truck. I wiped everything down and sprayed everything with CRC Electric Cleaner. That dried everything up and gave everything a “chalky” dry look. I then went out on the expressway and did a 10 mile loop at speed. I looked under the truck and saw MINOR signs of fluid but wasn’t sure if it was residual from earlier. I let the truck sit for a few hours and after dark I climbed under with a camera and flashlight. There was some fluid around the seam of the “dust cover“ and a little around the seam on the transfer case. I took some photos. It looks like there might be a crack in the transfer case…it looks moist around there too. I keep my U-joints greased and don’t hammer my truck. What would cause a crack in the case? I replaced it about 100,000 miles ago. Can I just change the face plate without dropping it or do I need to drop the whole thing? Also is this something that HAS to happen now or can I baby it and live with it for a little while? It’s not dripping enough to make a drop or puddle on the driveway. My truck has 250,000 miles on it btw.
Is it possible or realistic to braze the crack?
Any thoughts?

Thanks y’all

 

[BILT4ME]

Yes I posted on the Cummins forum but you guys are usually much more responsive.

I was getting ready to take a long trip in my 2007 5.9 automatic to pick up a 12 valve manual truck I’ve been wanting for awhile.. 1200 miles with a hauler on the back. Before my trip I changed my oil, checked ALL the fluids and greased ALL the fittings. My trans fluid was about a quart low and when I climbed under the truck with a flashlight there were drops of trans fluid on the pan and transfer case as well as coating the underside of the truck. I wiped everything down and sprayed everything with CRC Electric Cleaner. That dried everything up and gave everything a “chalky” dry look. I then went out on the expressway and did a 10 mile loop at speed. I looked under the truck and saw MINOR signs of fluid but wasn’t sure if it was residual from earlier. I let the truck sit for a few hours and after dark I climbed under with a camera and flashlight. There was some fluid around the seam of the “dust cover“ and a little around the seam on the transfer case. I took some photos. It looks like there might be a crack in the transfer case…it looks moist around there too. I keep my U-joints greased and don’t hammer my truck. What would cause a crack in the case? I replaced it about 100,000 miles ago. Can I just change the face plate without dropping it or do I need to drop the whole thing? Also is this something that HAS to happen now or can I baby it and live with it for a little while? It’s not dripping enough to make a drop or puddle on the driveway. My truck has 250,000 miles on it btw.
Is it possible or realistic to braze the crack?
Any thoughts?

Thanks y’all

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That looks to be an aluminum case. It can be TIG welded.

That looks like a casting flaw or someone ran over something or placed a jack under there.

Find a guy or company that welds Big Rig semi fuel tanks and take it to him. $200 and he'll weld it in place if he's worth his salt.

Clean it with CRC right when you get there. Then he can gouge it and weld it.

I have a friend that welds fuel tanks on semis while they are full for $100 per hole. Some trucks (cattle haulers) will come in with 10 holes in their tanks from rocks on the gravel roads. He'll make $1000 for about 4 hours worth of work. TIG'ing them while full is not a big deal because if you have your TIG gas pressure turned up a bit, there is no oxygen to allow the fuel to ignite. Fuel will drip out until he gets it sealed. Mind you, this guy's been doing this for 20 years and he's literally the best TIG welder I've seen. He welded a high pressure AC line for me on a car that never leaked again.

 

[bobm]

Yes I posted on the Cummins forum but you guys are usually much more responsive.

I was getting ready to take a long trip in my 2007 5.9 automatic to pick up a 12 valve manual truck I’ve been wanting for awhile.. 1200 miles with a hauler on the back. Before my trip I changed my oil, checked ALL the fluids and greased ALL the fittings. My trans fluid was about a quart low and when I climbed under the truck with a flashlight there were drops of trans fluid on the pan and transfer case as well as coating the underside of the truck. I wiped everything down and sprayed everything with CRC Electric Cleaner. That dried everything up and gave everything a “chalky” dry look. I then went out on the expressway and did a 10 mile loop at speed. I looked under the truck and saw MINOR signs of fluid but wasn’t sure if it was residual from earlier. I let the truck sit for a few hours and after dark I climbed under with a camera and flashlight. There was some fluid around the seam of the “dust cover“ and a little around the seam on the transfer case. I took some photos. It looks like there might be a crack in the transfer case…it looks moist around there too. I keep my U-joints greased and don’t hammer my truck. What would cause a crack in the case? I replaced it about 100,000 miles ago. Can I just change the face plate without dropping it or do I need to drop the whole thing? Also is this something that HAS to happen now or can I baby it and live with it for a little while? It’s not dripping enough to make a drop or puddle on the driveway. My truck has 250,000 miles on it btw.
Is it possible or realistic to braze the crack?
Any thoughts?

Thanks y’all

View attachment 3599073

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View attachment 3599075

If it ain't leaving Harley tracks then don't worry and keep Eye on it! If it gets worst then look a dropping it to weld or grind a "V" in the crack and JB weld it

 

[Bigstar]

You know….. I would have bet a $1000 that was a crack. Another guy on another forum said it was just a bad casting line and NOT a crack. He said the trans fluid wicked from somewhere else. I cleaned the area with electric parts cleaner because it dried and left the area “ chalky”. I drove the truck and found that I have a slightly leaking gasket. The leak is still there but not get worse and not very bad. I did a 1300 road trip hauling a trailer with no issues but yeah I am keeping and eye on it! Thanks.
Yikes! I don’t think I would let anyone TIG weld on my tank with fuel in it. I wouldn’t let them TIG an empty tank while it was on my truck ha