trans cooler pressure line threads stripped

[Snowmanak406]

everyone loves stripped threads right...
so i am experiencing some issues on a tranny rebuild.
trans was rebuilt and go to re-install it mounted up to the engine and get everything hooked up and look at the threads for the pressure line of the trans cooler line and threads definitely looked chewed up, didn't notice before as my experience, this hasn't necessarily been a common issue.
trans had not been leaking from this point up to removal either so i wasn't really looking here for a problem.
either way go to tighten it up, going slowly knowing they are weak threads, lo and behold, they strip.
now i am trying to find a way to rectify this issue, and had a few ideas on a way to possibly fix this short of getting a new case.
one thought, is to drill it out, tap in a 1/2" npt tap and install either 1/2" by 3/8" bushing or a 1/2" by 3/8" barb fitting (depending on what i can find). now my main concern on doing this is, there is not a lot of material on the protruding part of aluminum. (has anyone tried this before?)
second thought, drill and tap to a 7/16 unf add sealer to the threads and install a unf to NPT adapter https://www.mscdirect.com/product/details/80258544
Third thought; use either an oil resistant epoxy or JB weld to coat the threads and tighten and install.
Fourth thought; install a washer to fit tightly around the threaded area of the barb fitting, and JB weld trans to washer and washer to fitting.

any ideas or other methods that you have had luck with would be greatly appreciated!
-Michael

 

[dapepper9]

So you removed the entire fitting, not just the line? It's an NPT to AN union then has a B-nut on the line. Most just leave the fitting in the trans and take the line off.

Sound like you're going to have to drill it out and go with the next size up.

 

[Snowmanak406]

yeah, one of my friends have been helping me with the rebuild, and don't necessarily know why he decided to remove it from the case over removing the hose clamp. i don't think it is a factory set up as the other line was completely redone, but the fitting there is in the picture below.

 

[Snowmanak406]

then it goes to 3/8" trans lines to the cooler. all soft line there was part of the metal line left but it was pretty damaged so as it was installed was removed and replaced all soft line and rerouted.
my main concern is the amount of material on that piece of aluminum sticking out.

i know it is off a sonnax repair kit but best picture i can find quickly.
have you had to do this repair before?
just wanted to see if anybody else has and worked for them or not.

Thank you!
-Michael

 

[dapepper9]

Ive never seen this one no. Factory setup uses hard lines and most pull the hard line off. That's weird that it's like that.

It's too bad you already have it in the truck. Maybe you can find a guy with a mobile tig welding setup who could just weld a fitting to the case?

 

[Snowmanak406]

Sadly I dont know anyone set up with a tig welder. I can tig weld myself as well but same issue. Though onto that point I am curious about high heat jb weld putty, to fill in the hole then let that cure and drill and tap as it does say it is capable of that. And 600psi at 400F. I have honestly never used job weld before, for the most part I have been blessed with the luxury of being able to replace/repair the part by other means.

 

[Snowmanak406]

May be a dumb question, but could you post a pic of the actual part that should be and/ or even a part# I've been trying to search it, but it keeps giving me 1/4" line size, or that repair kit for 1/4" line. Or am I missing something and that is correct?

 

[dapepper9]

This is about what it looks like. NPT to AN thread. However, I'm unsure of size. Actually i myself have been looking lately as well because my recent project requires replacing that line with a braided hose. I do not wish to simply pull the line at this time lol

 

[Snowmanak406]

Mine is a 3/8 npt that the line goes to, It looks like that hole was unchanged from factory but it might have been altered before. Thank you for the pic. Appreciate it.
-michael

 

[Snowmanak406]

So I looked at this closer, and correction to above, it is a 1/4" npt male fitting with a bushing then a 1/4" compression to 1/4" comp fitting to 3/8 hose barb.