I have a 4L60E with a hole in the bellhousing, along with a large crack that goes pretty much the whole rest of the way around. I can literally move the front part slightly by hand. The car drove fine with it like that...we didn't even know the damage was there until we took a good look underneath. Is there a way to fix this, or are we going to have to get a new tranny?

 

So basically, the trans is pretty much free-floating in the front? That ain't good, and I wouldn't leave it like that for long since you could be doing some damage to the input shaft of the trans. What made the hole?
You can Mig weld aluminum, or have someone do it for you. You need to use argon gas. You also need to use a spool gun (wire in the gun not the welder box), because the aluminum wire is too soft to get pushed that far. It might be able to be done while still in the car, depending on how accessible the crack is.

 

I had a similar problem. I called a local welding company that advertised in yellow pages. They sent over two welders and a truck with an entire welding shop in it, Finished the job in about 30 minutes, but the transmission had to be out of the car. Charged $275 for a 4" crack, and a broken ear. Worked out perfectly.

 

tranny's already out of the car, but the damage it's got sounds more extensive than yours, pete. The front part doesn't move easily or significantly, it's just that it can move. And I have absolutely no idea how the damage happened. It looks as if something came loose by the torque converter, clattered around for a while, then spat out. The torque converter on the car when we got it did look slightly newer. I don't know how long the previous owner ran it like that...but seeing how he ran it for 3-4 years not running on all cylinders, it probably was a while

 

I have a 96 4l60e with 34,000 miles on it. I removed valve body cleaned it all up, put new gaskets in it. let me know if you want it 350 shipped....