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D18 e-brake lever pivot broke

Discussion in 'Early CJ5 and CJ6 Tech' started by supertrooper, Oct 9, 2011.

  1. Oct 9, 2011
    supertrooper

    supertrooper Member

    moreno valley, ca
    Joined:
    Nov 12, 2007
    Messages:
    749
    i finally got my trans and t-case out to start overhauling them. when i got them seperated and started taking off the e-brake i found that where the stud in the t-case that the brake lever pivots on broke. i looks like the stud is a light press fit and is held ing by a pin. the pin thats left is very small and might have broken in half.

    i am thinking about putting the stud in and welding it in along where the cast iron broke. any other ideas on how to fix it?

    [​IMG]
     
    supertrooper, Oct 9, 2011
    #1
  2. Oct 10, 2011
    w3srl

    w3srl All-around swell dude Staff Member

    Port Orange, FL
    Joined:
    Nov 6, 2002
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    4,275
    Given the amount of stress that is on that pivot and the limited success I've had with welding cast iron I would think about sourcing another case.

    Yeah, I know you can weld cast iron and have it hold but you need someone who knows what he is doing and can pre-heat the housing before welding.

    OTOH, if it breaks while the parking brake is holding the Jeep, well you get the idea.
     
    w3srl, Oct 10, 2011
    #2
  3. Oct 10, 2011
    supertrooper

    supertrooper Member

    moreno valley, ca
    Joined:
    Nov 12, 2007
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    749
    i know that cast iron has to be preheated and i have access to a torch it just been a few years since ive welded cast iron. im hoping that i dont need a new case since other than the outside being caked in dirt and gear oil all the internals and bearings are in great shape and just need a seal kit. there is a big scrape on the top of the stud and looks like some how the PO hit it with something. that might explan the dent on the rear driveshaft too.
     
    supertrooper, Oct 10, 2011
    #3
  4. Oct 10, 2011
    timgr

    timgr We stand on the shoulders of giants. 2022 Sponsor

    Medford Mass USA
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    Aug 10, 2003
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    23,596
    Dana 18s are not rare. I presume that's in the case? If it were mine, I would not even consider fixing it. Instead I'd look for a replacement case. Will a Dana 20 case work here? I'm not sure whether it has the boss for the parking brake, but your gears will go in a D20 case. A D20 case is usually considered an upgrade for the D18.
     
    timgr, Oct 10, 2011
    #4
  5. Oct 10, 2011
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
    Joined:
    Sep 23, 2002
    Messages:
    12,529
    That's in the rear output housing. Really not rare although that is a very common problem. About half we get in at the shop are broken or damaged. Usually from someone having it out and not being careful.
    I'd just get a good used output housing and be done with it. Put an ad in the classifieds section or check out the "Where to buy parts" sticky at the top of the section.
     
    nickmil, Oct 10, 2011
    #5
  6. Oct 10, 2011
    tomtom

    tomtom Sponsor

    Huntington Beach, CA
    Joined:
    Jun 20, 2007
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    tomtom, Oct 10, 2011
    #6
  7. Oct 10, 2011
    supertrooper

    supertrooper Member

    moreno valley, ca
    Joined:
    Nov 12, 2007
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    thanks for the info guys. if icant find a cheap replacement output housing ill try the repair in the link. :beer:
     
    supertrooper, Oct 10, 2011
    #7
  8. Oct 12, 2011
    jeep2003

    jeep2003 Well-Known Member

    Upstate NY
    Joined:
    May 30, 2006
    Messages:
    1,928
    maby make a bracket that bolts to the pan bolts to brace the top of the stud. I guess your jeep doesnt have a skid plate?
     
    jeep2003, Oct 12, 2011
    #8
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