I just discovered this crack in my transmission housing. Took it to the dealer and got a $1,900 estimate based on replacing the entire transmission casing. Isn't there a way to just have the end welded back on where it broke off?

 

You can have it tig welded. You will need to find someone to do that. You could JB Weld. I used JB weld on a transfer case on a 85 Chevy blazer once. It held up to a lot of off roading abuse. Same kinf of repair, one of four mounting bolts to the transmission case.

 

I’d try JB Weld and if it cracks again go get a reputable shop to weld it.
Replacing it would be my last option.

 

I'd be curious as to the lower bosses condition as well. If they're both broke, I'd look into why the exhaust bracket put so much stress on the tranny case. Otherwise any fix will fail again.

 

I'd skip the JB Weld and go right to the welder.

 

I would think a strike to the exhaust could cause that to happen. You could inspect the underside to look for marks. It could also be from over tightening using an impact. It might not have broke while tightening but later in time due to the stress.

On the JB Weld plus side. You can do it without taking anything apart. Just clean and apply right there in your garage. To tig weld it you would need to remove the case from the bike.

 

You don't say year or show exhaust, but that is the mount for the extension hanger for the exhaust pipes isn't it?

If that's the exhaust mount, are you fixed with the ability and tools to saw a piece of 3/16" steel or 1/4" thick aluminum flat stock and drill 3 holes?

How I would fix it. Basically with a neat finished oval shaped with full radius on each end bracket that attaches and shares the two bolts further up on the transmission. The lower bolt below broken one is still holding up exhaust.

I would pull that broken part correct and paper template the new bracket.
You need to careful drill it so it's keeps the broken peace in line. Going to need three longer bolts and maybe some washers to shim all face square to the new bracket.

Done neatly, especially the hole spacing, with the bracket smoothed and rattle can flat black would look like factory. Aluminum would be easiest to work. It will hold if hole placement is good enough so outside of bolt keeps it in line.

I have a drill press and vice but I probably would still drill it small and finish approach it with a round file.

Now I say all the above because I attempt to stay in what most may attempt.

I actually myself would finish it on my vertical mill.

However my guess is a small shop probably has a 4 hour minimum rate, but that's a 1/4 of what quote you got.

Now I am economal, and had a small shop. Now like Puff, that's all in the care of other hands

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And I know..

 

I'd definitely take the whole bracket off and have a closer look. It looks like the bracket itself was welded at some time in the past. Now the case proved to be the next weakest link...

 

What year and model is your bike? Do not bother with JB weld. There is simply to much shaking and vibration for that to last. If it were mine, I would remove and strip the case and take it to a certified welder in aluminum. I've welded many a Harley crankcase, primary case and transmission case and, properly done, that will be very satisfactory. That would be my first choice.

In the alternative, there are many used 6 speed Harley-Davidson tansmissions available online at eBay. (no affiliation), Prices run from $400 to over $1,000. Good luck.

 

Talk to a welder before you think about JB Weld.