I have a 4L60E with a 6 bolt output side that came with an electronic trans case. I want to put in a manual trans case but the shifter needs a special adapter thats shorter than my stock one and uses a 4L60E with 4 bolts on the output side.

Could I cut my adapter down and weld in the section I need with the shifter mounting bolts? The adapter could be welded inside and out.

sSmply put, can I cut an adapter in half and weld it back together?
thanks

And yes I did a search and got mixed reviews on welding cast aluminum.

I busted the cast bellhousing on my amc 6 once. I could not get tig to weld cleanly due to impurities! Mig welding wad too cold - no penetration. I finallyused a stick welder to fix it. The good thing about using a stick is it burns real hot and fast and is not as suceptable to contamination as mig or tig.

Cast aluminum is pourous and will absorb all the grease and oil that has spilled on it. You need to clean and slightly grind the crack, sandblast it, then use a stainless steeel brush to remove the minute bits of sand left by the blaster. Jig the bellhousing up so the crack is seated and as close to original as possible then burn it. Hot and fast.

I used to use a torch and stick rod the same process as brazing.
I don't remember the temps. but the flux on the rod will melt just before the aluminum. Works good on thicker aluminum. Just make sure that it is really clean.

I can't answer your question concerning the adapter- that would be a matter of you being able to get the parts true , etc.
Now as far a welding the ALU I think you should have absolutelt no problems. All aluminum is porus , yes they can all "soak" up junk but so what you know that so you clean as best as you can. While throwing down your first pass if you are having big problems with contamination re-grind , and clean, start over. There are off the shelf chemical cleaners at the welding store that will help you out alot.
Anyways I have never not been able to fix any cast aluminum part whether it has been bellhousings , or out board motor housings. In fact I would consider this some of the easier work that I do. All repairs are ALWAYS made using TIG. Although I have used the other process mentioned above(not for these kind of repairs) I personally would not use them in this instance- If someone comes back because the item does'nt work I lose money!!!
weldpro

I used to weld up and repair cast aluminum boat propellers (tig). How they welded depends on the quality of aluminum that was used. For example volvo brand props could be welded and there would be no pin holes at all, but mercruiser props usually had pin holes all along the length of the weld. Like others have said, clean the weld area very well. I sandblasted the area to weld and I think that is the best method.

I won't be doing the welding myself. I will definitly have someone do it. I have a machinist friend who can cut the piece I need to fit. I will check with him if he knows anyone he really trusts.
I just wanted to know before I go hacking up my adapters.

It was either this or get a new tranny, and mine only has 50K on it.

Thankyou everyone for your input. I can take stuff apart and put it together all day long but this tech stuff gives me problems and I enjoy learning.

I recently saw a 6-bolt to 4-bolt adapter on a website. They use it on overdrive conversions on streetrods I think. Try 700r4.com or kdsperformance.com. I'll try to find it again and let you know where it is.

Ok I found the adapter through a company called JTR. It's not listed on their website, but I found another person who bought it from them. I don't know if it will work because the 2 new adapters need to equal the length of the factory adapter. Looks kinda close, plus I'm curious of the price of the 6-4 adapter.

thanks