Hey Gang,

Sad news in sad town, recently my girl lost a pint of oil in 20 miles (multiple incessant drips off of the bottom of the motor) and I figured the upper oil pan gasket was leaking where it meets the block...Wrong!

Apparently I cracked the upper oil pan itself... how does one rectify such a situation? Take it down and braze it? Do the oil sump chain and timing chain while I am in there? What are your guy's thoughts? You can see it's on both sides of the gusset.

Sorry for the errant lighting!
https://www.youtube.com/watch?v=ZvRJcM5tbFw&feature=youtu.be

What engine, year etc... fill out your signature.

The upper pan is aluminum. Don`t think it can be brazed, would have to be aluminum welded. You will probably have to remove it and clean it real good to get out the oil in the crack.

Second option is get a pan from another like type engine.

Do not use brake Cleaner to clean before welding. even though it has vaporized, there is chemicals that when welding, the fumes can kill you, or wish you were dead. see if I can find the link.


Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Hey Charlie,

I hear that, I think it's phosgene, thanks for the look-out!

(I try not to use anything more volatile than acetone or methanol. I work in a lab and we use methylene chloride for extractions (also works well for welding plexiglas); but there is no way I would use that anywhere but under the fume hood.)

Could I use something like the HTS-2000, Duraweld, Alumaweld, etc. aluminum brazing rods? Does anyone have experience with this method for cast aluminum?Even the toluene from spray painting outside,

Here is the article I was looking for. This is a good for all to read.

Brake Cleaner = Phosgene Article

Here is a Google search of further reading if anyone doubts this guy.
https://www.google.com/#q=welding+dangers+of+brake+cleaner

Be safe, is what it all about.

Iam not a welder so can`t comment on what to use. I did buy some of those welding rods from a guy at a car show, where you use a Propane Torch, maybe Mapp gas, and he can even weld beer cans. Don`t plan welding my Beer Cans together but was impressed. Something like that might work on your pan.


Charlie

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Hey Charlie,

Thanks for the article, certainly everyone should be aware!

It's an '83 OM617, I will apply a sig.; and that rod is just what I was wondering about. Anyone tried it?

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72% 1992 FJ80 + 17% 1983 OM617 + 10% 85/87/92 4Runner + *Eclipse/GMC = 100% Truck
(*<1%)
Build Thread: http://forum.ih8mud.com/threads/a-humble-fj80-om617-r151f-swap.759554/

I found some of hose in a tool box that I never open up. I've had them for years & never used them. I wonder & am hoping they work.

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85SD 240K & stopped counting painted, putting bac together. 84SD 180,000. sold to a neighbor and member here but I forget his handle. The 84 is much improved from when I had it. 85TD beginning to repair to DD status. Lots of stuff to do.

I am not sure on the spelling but Harbor Freight sells Rods for welding Aluminum called Alumiloy. They welding temp is 750 Degrees F.

I bought some but have the project I planed to use them on never got off the ground so I never used them.

Other Places besides Hrobor Freight sell them. It is likely a large Chain Hardware store sells them.

However, I think the real issue is if the Pan should come off of the Engine. If the Pan has to come off you there is a decision if to let an actual Welder do the job or not.

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84 300D, 82 Volvo 244Gl Diesel

Brake Cleaner = Phosgene Article

Phosgene Gas was one of the Gasses used in WWI. If you do expose your self to it don't do like the Guy in the Article did. He tried to self treat himself and it sounds like He has some life long damage.

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84 300D, 82 Volvo 244Gl Diesel

Do you want me to delete the links?

I don`t want to mislead anyone.


Post your findings.

Charlie

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Had a crack in a 240D upper oil pan. Removed the pan, drilled a hole at each end of the crack and holes along the crack itself. Filled the crack and holes from both sides with JB Weld and drove it for many miles without a problem. Your mileage may vary

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"Rudeness is a weak man's imitation of strength" - Eric Hoffer

It will probably depend on where, and how large, the crack is located. Many cracks could probably be repaired with JB Weld. Welding is an option but unless you are really experienced at aluminum welding, it is really difficult to make a repair that will last.

If it is in a major structure area, it is likely to crack again and usually at the most inopportune time. In that case, I would definitely find a used replacement.

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Sam

84 300SD 350K+ miles ( Blue Belle )

Welding would most certainly warp the oil pan and create the potential for even more leaks. I know someone who attempted to make some mods to a Mercedes oil pan and even with the pan bolted to a block during welding warped beyond use. He ended up fabricating a whole new pan in steel.

I think it would be possible to use the Aluminum "welding" rods to fix the crack as the temperature used is so much lower. That stuff is really tough. To get enough heat using propane I think you'd need two torches one on either side. MAPP gas would probably do the job. Get it really clean.

If I were going to try it I would still use a skim coat of JB Weld on the inside after "welding" to ensure a good seal. Be sure to stop drill the crack to relieve the stress before "welding".

All that said, your best bet is a trip to the junk yard to source a new pan.

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Current Stable

• 380SL (diesel)
• Corvette C5
• Manx
• Baja Bug
• F350 Powerstroke
• Auburn Boattail Speedster replica

JB Weld does better when it is surrounded as in filling a hole than when it is skimmed on filling a crack.

I have used it to seal a metal water tank around where a fitting went through the wall. The JB had some irregular surfaces to attach to.

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85SD 240K & stopped counting painted, putting bac together. 84SD 180,000. sold to a neighbor and member here but I forget his handle. The 84 is much improved from when I had it. 85TD beginning to repair to DD status. Lots of stuff to do.

I've successfully fixed a cracked pan with aluminum solder (from mcmaster.com). The only problem is getting enough heat on the spot, as an aluminum pan is a marvelous heat sink. I can't imagine how much heat you'd have to apply to actually warp it. i did have the pan off the car, not sure you could do it in place without ruining the gasket. I didn't have much luck with JB Weld for this, not sure why, but I just couldn't get it to seal permanently.

I don't use many cleaning solvents. For everything but the heaviest greasy dirt, I use water and Dawn dish washing liquid. Scrub with a nylon brush, and you can get most anything grease and dirt free, with no nasty fumes or toxins.Even unpainted steel can be safely washed this way, as long as it's dried afterwards. Every summer, I buy a large plastic storage container, where I dump my dirty dishwashing liquid. I just leave it in a corner of the garage and let the water evaporate. At the end of the season, I let it completely dry out. The plastic tub ends up covered with thick tar. I just put the whole thing in a bag and send it off to our county trash to power plant. Clean, efficient and non-hazardous.

Oh man that bites. If you need help in the yards down here let me know.

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617 swapped Toyota Pickup, 22-24 MPG, 50k miles on swap