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Discussion Starter #1 (Edited)
Every time I have pulled the clutch cover off to check and clean the area, I had a ton of dust. Now I know why. It appears the last time I blew a belt it caused damage to the top of the back cover where the air exits the clutch box into the engine
5439086 DUCT-CLUTCH,AIR INLET has a tear and deformation:Also not the top of the Inner Clutch box has been worn away. I am going to pull the clutches this week and attempt to weld it all back to useable condition. If that does not work I will have to buy a new inner clutch box and air duct. $$$$$$#!t.
 

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<font color="#000000"><span style="font-family: &quot">Every time I have pulled the clutch cover off to check and clean the area, I had a ton of dust. Now I know why. It appears the last time I blew a belt it caused damage to the top of the back cover where the air exits the clutch box into the engine.</span></font><br>
<font color="#000000"><span style="font-family: &quot">5439086 DUCT-CLUTCH,AIR INLET has a tear and deformation:<br></span></font><img src="https://www.prcforum.com/forum/attachment.php?attachmentid=125415&stc=1" attachmentid="125415" alt="" id="vbattach_125415" class="previewthumb"><img src="https://www.prcforum.com/forum/attachment.php?attachmentid=125417&stc=1" attachmentid="125417" alt="" id="vbattach_125417" class="previewthumb"><br>
<img src="https://www.prcforum.com/forum/attachment.php?attachmentid=125413&stc=1" attachmentid="125413" alt="" id="vbattach_125413" class="previewthumb"><br>
<font color="#000000"><span style="font-family: &quot">Also not the top of the Inner Clutch box has been worn away. </span></font><br>
<font color="#000000"><span style="font-family: &quot">I am going to pull the clutches this week and attempt to weld it all back to useable condition. If that does not work I will have to buy a new inner clutch box and air duct. $$$$$$#!t.<br>
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</span></font>
The pics came through


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Discussion Starter #3 (Edited)
Plastic Repair

This was a plastic welding day. I found three places on the inner clutch cover to weld up and one was a fairly large triangular hole about 1.25 x 1.5 inches. Another was just a crack about 1 inch long. The third was the seal groove where a broken belt had taken out the inner part of the grove wall about 3 inches long. When we took the inner cover off, we discovered a seepage on the primary – I think my maintenance plan should cover that.
The other part today was the roof. I had a long crack on the rear of the passenger side about 2 inches to the left of the last screw. And an older crack from hitting a limb over a year ago.
All the welds had 1/32” stainless mesh imbedded into the plastic then filled and smoothed it over. I think it looks fairly good myself.

Thanks Ken for you facility and assistance.
 

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Discussion Starter #5
Good news from the Stealer, my extended warantee will cover most of the repair minus the deductible. The labor alone will be intense, I hope they put everything back together with the correct torque values and in proper sequence. Just glad I don't have to participate I know less than nothing about pulling apart an engine.
 

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Discussion Starter #7
The service writer (Tech) told me all I would pay was the deductible. Last year when my rear and front windshields were broken that is all I paid, $50.00 deductible.
 

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Discussion Starter #8 (Edited)
Well we got the wrong part so I won't have a Ranger for the month. I have a picture of the weeping primary. Weeping inner clutch seal and cover.jpg They discovered the rear half shafts are weeping and that will be a seperate warantee cclaim. Eventually when the web site lets me I have six pictues to upload:
Outter box seal groove.jpg Exhaust vent outside.jpg Inside box cover.jpg Clutch box exhaust duct.jpg
The welds could have been smoother but it was the first time I worked with my new plastic welder. Each weld is held together with 1/32" stainless mess screen inbedded in the plastic. Then I added more plastic on top of it. IF and when I take the inner cover off again I will try to smoot it out some with a heat gun and the welder.
 
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