Metal working – Method of mechanical manufacture – Repairing
Reexamination Certificate
1999-10-12
2001-02-27
Hughes, S. Thomas (Department: 3726)
Metal working
Method of mechanical manufacture
Repairing
C029S402060, C029S898010, C408S079000, C408S080000, C408S093000, C408S094000
Reexamination Certificate
active
06192567
ABSTRACT:
BACKGROUND OF THE INVENTION
The invention relates to a repair kit and process for repairing damaged transmission housings. More particularly, the system of this invention enables reuse of a damaged housing which would otherwise have to be discarded due to a bore which has become enlarged or worn to the point that the housing is no longer serviceable or repairable by conventional means.
Automotive automatic transmissions conventionally contain a number of moving parts and pins which must be precisely fitted to other transmission components, often through a precisely positioned and dimensioned bore or other cooperating or connecting devices.
Various repair methods for repairing worn housings have heretofore been proposed. However, none of the methods have been successful in actual practice. For example, a worn part could be welded and a new bore drilled therethrough. However, this procedure has not proved to be practical due to the impossibility of correctly aligning the tools for redrilling, particularly, utilizing the tools present in the typical automotive repair shop.
In view of these limitations a need has existed for an improved system for repairing automotive transmission housings.
SUMMARY OF THE INVENTION
It is a principal object of this invention to provide an improved system including apparatus and processes for repair of worn bores or apertures in transmission housing cases. It is a related object to provide such a system which enables repair of such housings, which previously had to be discarded, the repair being accomplished in a typical automotive repair shop using commonly available tools.
In accordance with an important aspect of the invention, a drilling jig is provided which closely fits within a chamber, such as a servo bore, of a transmission housing. In accordance with a related aspect, the drilling jig has an opening that enables accurate placement of drilling guides. In accordance with a further related aspect, the drilling guides are accurately positioned in alignment with the worn aperture to be repaired, with respect to both position and angular alignment thereof. In accordance with a further aspect, the drilling guides are provided in increments as to diameter of a guide bore contained therein so that the opening can be gradually and precisely enlarged using reamers instead of drilling devices. In accordance with a still further aspect, the bushings are held in place by the drilling jig, which is provided with a further mechanical fastener that prevents rotation of the drilling guide bushings when a reamer is being rotated therein.
In accordance with a still further aspect of the invention, a replacement bushing is provided which contains a new aperture precisely sized to replace the worn aperture and which tightly fits within an enlarged, reamed diameter of the original opening. The replaced aperture is axially in precise alignment with the original axis of the opening. In accordance with a still further related aspect, the replacement or repair bushing is tightly fitted within and adhered within the enlarged aperture utilizing suitable adhesives.
Briefly, the invention provides a process for repairing a defective opening in an automotive transmission housing includes the steps of (a) providing a drilling jig sized to fit closely within the servo bore chamber, the drilling jig having an alignment aperture concentric with the opening when fitted within the chamber, (b) inserting into the opening a bushing which closely fits within the opening, the bushing having a central reamer guide bore with a diameter larger than the original bore diameter, (c) inserting and rotating a reamer in the reamer guide bore thereby enlarging the diameter of the opening, (d) providing and inserting a repair bushing into the enlarged opening, the repair bushing having a central opening with a diameter equal to the original diameter and having an external diameter equal to the diameter of the enlarged reamed opening. An adhesive may be used to fix the repair bushing in the opening. In the preferred embodiment, the jig includes a threaded bore laterally displaced from the alignment aperture wherein a set screw is threaded, the bushing having a shoulder which is provided with an indentation on its perimeter engaging the set screw whereby rotation of the guide during the reaming step is prevented. Two reaming steps may be performed using progressively reamers and reaming guides.
Further objects and advantages of the invention will be apparent from the accompanying claims, the following detailed description and the accompanying drawings.
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Hughes S. Thomas
Omgba Essama
Ryan Kromholz & Manion S.C.
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