The good times just keep rolling.

History on this.

Picked up a 2009 Cobalt SS that turns out to have transaxle issues.

I pick up a decent one out of a HHR SS.

It looks mint, I put it in and it works beautifully.

Fast forward a month and I need to pull it again because the choice of clutch when installing it a month ago was poor.

When pulling it out I found one busted bolt hole. It's the front *closest to radiator* bolt hole.

I have the piece, it was sitting there loose.

The only thing I can figure is when the HHR that it came out of was hit this bolt took some impact and I didn't detect the crack when installing the trans. When I installed it everything torqued down just fine but it had to have had a hairline fracture that I didn't detect.

#1 Does anyone know if someone who can weld this stuff will be able to do the repair in the car? I can pull the mount out of the way in a minute and it's pretty clear access.

#2 Do you guys think this bolt by itself sees much stress? I am going to be driving the car a little while *very easy on it* until I can figure it out.

#3 I do have a spare case half but would really REALLY like to avoid pulling the trans AGAIN and would like to avoid even more having this perfectly working trans totally dismantled to have the parts swapped over.

Any RELEVANT and EXPERIENCED input is appreciated!

EDIT: I have NEVER induced any wheel hop and would instantly stop should I feel it coming on.

 

One thing I was quite disappointed in is the fact that the engine has an alignment hole REALLY close to where this bolt goes but they do not line up. I figure this must be since they used a Saab trans with a GM engine? Just a theory.

If those holes lined up I could have that tab welded back on, drill it out and use a longer bolt + washers on each side to sandwich it together for extra support.

The car has four mounts, I'm really hoping this front one that's 1/2 failed isn't seeing a ton of stress under normal driving. I'd hate to make it worse.

 

I would say you could have it welded, but most likely you would have to remove the trans and have it done out of the car for strength and reliability, and also to re-tap the threads after as they will be melted somewhat during welding.

 

Damn man that sucks

 

shouldnt be too much of an issue to weld the piece back on with the trans in the car, as long as they can get to it properly to get the tig torch in there. once its welded you should have a clear shot with a drill to drill and re-tap it, may have to use an angle drill. the hard part will be finding someone in your area that can tig weld aluminum and has a hoist. may be able to be welded with a spool gun but i dont think you can get it in there as spool guns are bulky.

i dont know if clear image automotive is still around any more. they used to make some beautiful exhaust systems and headers for the cobalt, and a pile of other stuff too. they were in tacoma iirc. if they are still around im sure they would have the equipment required.

 

Thanks guys.

I think I'm going to degrease, prep the surface, degrease again and go with some good two part epoxy as a first try. If this fails I'll go from there.

 

Jb weld ftw haha. Worth a shot i guess

 

In for results, i have a low mile (80k) 3.82 trans sitting in my garage with the same fracture. will sell cheap btw lol