Recurring cracking in transmission housing?

2008 FORD RANGER
157,000 MILES • 4.0L • V6 • 4WD • AUTOMATIC
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FORDFRICKENRANGER
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I owned my truck listed above for a year before the transmission cracked right above the pan and before the extension housing. Dropped the pan and extension housing months previously to replace the park rod. Replaced the transmission and 2 months later it cracked in the same spot as previously. I decided to weld the crack, and it worked for about 5 months, but it will no longer hold any fluid, I believe it blew a gasket or cracked again but I’m not certain of which. What would cause the crack to return twice and is it worth replacing the transmission again?
Dec 25, 2024 at 8:05 PM
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STRAILER
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Can you upload an image of the crack so I can see? You may have too long of bolts holding the transferase on forcing the transmission case to crack? The cases typically do not crack like that, can I ask how the transmission is shifting, or does it have a shift kit? If the line pressure is too high it can cause this problem, also do you have a check engine light on? If so, it might be a code for the pressure regulating solenoid is not working correctly, I need more information to help you.
Dec 26, 2024 at 1:45 PM
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FORDFRICKENRANGER
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Transmission works great, the only issue with shifting is if I let the fluid get too low. The transmission comes in 3 pieces; transmission, extension housing, and then transfer case. It’s cracked around where the transmission and ext housing meet. Wouldn’t even call it a crack, when I took it apart the piece fell out in my hand in both cases. Check engine light is on but unrelated to the transmission, it’s a code for running lean on bank 1.
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Dec 26, 2024 at 1:50 PM
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STRAILER
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Thanks for the images and video. It looks like the "alignment dowel" is missing which is supposed to go into the broken piece you are holding. Can you confirm it is not in the transfer case? If not, this is your problem.
Dec 27, 2024 at 10:23 AM