560SEC: Damage to trans tunnel from Failed front Flex Disc
 

I have noticed that while driving my SEC, there is a rather alarming amount of heat coming from the center console area, around the radio and shifter. It's heating everything up to the point where only hot air blows from the AC vents when the AC is on, and I am smelling a bit of exhaust gasses. The metal ashtray literally gets too hot to touch, it will burn you.

So while I was underneath the car changing the o2 sensor, I took a look at the center console/driveshaft area, and noticed that the driveshaft and almost all of the driveline parts have been replaced and look new. I was, however, shocked at the condition of the transmission tunnel...there are gaping holes in it and it looks like the car broke a flex disc at some point...

Looks like this, but not quite as bad:

http://dieselgiant.com/300SDL_rear_tran02.jpg

On the dieselgiant tutorial, they use "caulking" to secure a piece of sheetmetal in place. What kind of caulking are they referring to, and how would you go about fixing this problem?

http://dieselgiant.com/flexfailure64.JPG

Long strand (aka kitty hair), two part body putty has excellent structural rigidity once it's hardened. You can fill big gaps with it and it's very tough stuff. Available at any auto paint store. I would do some serious CO testing in the cabin.

You may have the heater vent door(inside the dash) open all the time and the heat from the heater core is dumping out behind the CCU and radio as well as the gaping holes. I'd check to see if they replaced the carrier bearing also and not just the flex disc.

As to repairs, how long and wide are the cuts in the tunnel? if not too long or wide then there is a metal epoxy available at the auto parts store in a tube. called Miracle Putty or some such name. It is a two part epoxy putty you kneed and use as much or little as you need. it hardens like metal and you can use a spatula thingy to apply to the cracks. Can be sanded and painted also
Good stuff.

I would weld it...