If cracked, you need to drill a 316 dia hole at both ends of the crack to prevent the crack from propagating. Is the housing cracked or completely broken into two pieces. I have an aging fleet of dm690s that are used in ready mixed concrete. Im currently in zambia in lusaka, weve managed to limp our way here after some dodgy welding to stopp the diff oil leaking and now looking for a proper repair. Vantage 300 kubota,miller 304 xmt,lincoln ln 25 pro, ranger 305 g, plenty of other tools of the trade to make the sparks fly. Front axle beams stabilisertorsion bar holes rebuilt and crack tested. Nov 01, 2009 welding dana 44 cast steel housing slinging molten steel. I guess if it makes someone nervous, he shouldnt do it, but i did and i love the result. Welding the axle housing on a monster truck part 1 duration. Although i also added some steel plate and threaded rod structure to better support the fel arms that originally caused the fracture. In this video i show you the process i use to weld up the axle tubes to the center section. Even with evenlyapplied welding, straightening was needed at the end of the line. Maybe reinforce the housing by welding a thicker plate over the cracked parts.
We are welding the axle tubes to the cast center section of the housing. Wait a minute am i to understand you want to weld the axle tubes to the housing or weld some thing to the axle tubes. These tubes are pressed into the center at the factory and plug welded in 3 places. I just tried to weld my 14 bolt axle tubes to the housing. Fixed danas and also used a mobile company that specialized in axle repair. This is a video about the long process of stitch welding cast to fix a crack on. I have started to replace rear axle housing due to corrosion from acid cleaners and cracks near the differential housing gasket flange. Use the lowest heat you can and still get penetration, because warping the tube is always a concern when welding on your axle.
Maybe the springs are too soft and is straining the axle housing which causes it to crack when under loadtorque. In the offroad and rockcrawling scene it is very common to weld the steel axle tubes to the cast diff housing. Guys, on my 89 lwb ive cracked my front diff housing for the second time and im thinking about either. The jb weld cracked when we pulled the cap off today, but you can clearly. From the factory the axle tubes are pressed into the differential housing, then they are plug welded through holes in the casting usually only 2 per side. I have notice the cracks always appear on the drivers side,under the bevel gear compartment and near the the gasket surface and. They all have the 44,000lb fabricated steel rear axle housings. Welding 2010 differential housing good advise jtmcc. This is a video about the long process of stitch welding cast to fix a crack on the axle housing of my johndeere 60. You can use stick, mig or tig, but make sure to go easy if you use stick welding cos its pretty strong way of doing it and the diff housing is generally not that thick and can bend with excess heat. Cracked gmc bell housing i had a 1993 chevy 2500 manual and it was the nv 4500 trans. My axle cracked at the same place and along the weld seams last year on my 402s. Give me some idea what i can weld it with for strength, because the rear from the factory only.
I welded a bell housing with stainless rod using an ac stick welder several years ago and its still holding strong. Looking to fully weld axles tubes to a cast center section to strengthen a rearend for a drag car. May 01, 2016 4x4 group suffers cracked axle tube near crankshaft junction in death valley. Is there a metal bondsealant that can be answered by a verified ford mechanic we use cookies to give you the best possible experience on our website. I know it sounds silly that someone who can fabricate and weld cant braze. What im wondering is if there are any welding specifications or procedures anyone can point me towards for reattaching the bracket onto the diff housing. Welding axle tubes to housing miller welding discussion. Welding new studs in is not a good solution for this application, even with the right wirerod. Feb 28, 2007 my rear differential housing has a hirline crack that will leak over time. Page 1 of 3 gusseted rear diff housings posted in new in the store.
Michael shows you how to choose the right diff guards for your 4wd. I drained fluids and removed the vent and replaced it with a 14 qd compressor fitting. Your ad is for a complete welded housing correct jim. Hairline crack in factory weld in front diff housing patrol. Use the spark test to determine if its cast iron or cast steel. Hi all have anyone ever had a issue with a cruiser bakkie 4. Welding at any other locations on the axle housing will void the warranty and can result in an early failure and unsafe operation of the axle. I have done a lot of welding on offroad truck axles. The center section would be located and clamped to a fixture. Remembering that last year while working on a friends car with a cracked diff housing, we dug out the crack on both sides and liberally filled it with epoxy. I removed the suspension and u bolts, so i could get in there and find the whole crack. Usually the diff oil takes the grease back in and it doesnt do the diff any good.
For drag racing usage we need to weld the tubes to the center to keep them from shearing the plug welds and spinning in the casting. Rather than welding the tubes into the diff housing. Failure to follow all steps of this procedure will result in a poor repair and the crack could occur again. You might get away with welding a bracket to the axle tube but not spring perches or welding the tubes to the center section with a 110 welder. The ultimate fix is to fully weld the tubes to the center housing, but theres some mystery and myth surrounding the process. Dec 01, 2015 this is a video about the long process of stitch welding cast to fix a crack on the axle housing of my johndeere 60. I picked up what i thought was a killer deal on a ball joint d60 from an f350 only to find it had a small crack in. I spoke with someone and they asked if it was cast iron or cast steel.
Stitch welding the axle housing of a johndeere 60 youtube. I preheated dephuc out of it 650 degrees plus and when i went to weld it with my mig welder i did about of the axle and when i took my helmet off it was already cracked down the center. The front diff housing on my 110 isuzu county has cracked around part of the weld at the front where the pan is welded on to the main part of the casing. But welding a differential is a very permanent thing it turns out, and it will have side effects when it comes to all of the times youre not doing a maaaad skid through a corner. I have welded brackets to cast with a mig welder and never had a problem, but if you wan to do it right, use some heat although i disagree with elusives red hot as soon as the welding is done throw some heat back onto it and let it cool slowly. This housing has been tested in a huge variety of events worldwide, from the winch challenges of australia to the first australian built rig that entered in the king of the. As shown in this detail view, one challenge that made this particular repair difficult to accomplish was the close proximity of the threaded holes to the pilot counterbore in the housing. You could even do it on the truck if you wanted, but best if you pull the housing and clean it up well first. My rear differential housing has a hirline crack that will. Today is the 10year anniversary of the shoes video.
Imperial engineering has specialised in the machining, welding, fabrication and. I have done similar work on a scout dana 44 axle housing differential castin perch. I would suggest that looking at the bottom of the housing proper will likely reveal an impact to the sump of the housing. Cracked 44,000 axle housings modern mack truck general. Cracked axle tube junction death valley weld repair death valley dazed. This right side axle housing was separating nearly 316 from bottom of this differential housing and the 58 bolts literally pulled out threads. Is the housing cracking because there isnt enough flex from the housing to the springs when the suspension is at its limits. He owns his own welding business and was a huge help getting me started and showing me what i needed to do even though he did no actual welding on it. Also hv a good friend that has a heavy frame shop over 35 years he straightens axles all the.
Leaking front diff case cracked weld defender forum. I was wondering whether it could be repaired by welding it. Gearbox casings and diff housing bearing housing rebuilt. I pressured the housing to a few pounds of air and sprayed soapy water along every weld seam. Diff guards bolton verse weldon superior engineering. I have a spare complete front end which i plan to check over then install, but first id like to strengthen the diff housing ie, the part the diff bolts into. It looks like i have cracked my gearbox, resulting in the slow, but sure expulsion of all of its fluids.