how do you weld your diff?

[finn188]

do you pull the carrier out and do it on a bench? also where exactly do you weld?

 

[IslanderXJ]

Why are you welding on your diff?
If you were going to throw in a junk carrier to keep it from warping.
Preheat and post heat... nevermind.... just don't do it.

Bridge over it and weld to that.

 

[finn188]

im welding it as an experament to see how long it will last. when it breaks i have an 8.8. just want to weld it as "correctly" as possible.

 

[IslanderXJ]

Are you talking about welding your spider gears in the carrier or to the axle housing?
Carrier: Pull it and do it on a workbench.
Weld the spider gears together completely, should look like a big ball o metal when done.

 

[finn188]

lol. no, i dont want to weld my diff cover on. so on a bench? do i just weld the gears or is it better to weld to the carrier its self too? thanks

 

[snow580]

You want to weld the gears together and weld them to the carrier also.

Like Islander said it should be one big ball of metal when your done.

When I weld mine I have always left the carrier in the axle assembly.
Taking it out would probably be better and cleaner.
I try to cover everything that is not getting welded like the ring and pinion with wet rags to catch any spatter.

Be careful not to get any weld on the axleshaft splines.

 

[j33pownr]

Since no one mentioned it, your gonna want to clean all the old gear oil off whether or not you do it in the housing so your welds dont get contaminated. I'd just use a whole can of brakeclean because it dries with no residue.

 

[asp]

i've also heard of people cutting bolts into wedges and using them as filler material between the gear teeth that aren't meshed together for more metal to weld to/with. if it's just a temp deal, i don't know if it's worth the effort or not for that. good luck and throw a pic up when you're done! side note: funniest weld job i ever saw - a lunchbox locker welded in... don't ask.

 

[Georgia Mike]

Weld the spiders only. That's what I did on my last XJ, and that was 4-5 years ago, and as far as I know, it's still going strong. Lots of people will argue that you should weld to the carrier, too, but I didn't want to risk stress cracking it, so I just did the spiders and called it a day. Also, get yourself a can of NON-flammable brake cleaner, spray it out, and weld it up. I didn't even remove the carrier, I just sprayed it out, and wrapped wet rags over the carrier bearings to protect the from weld spatter. When you're done, go through the insides to make sure there are no loose weld spatter boogers in there. If there are, chip them out before puttin the cover back on.

 

[jeep/bronco]

the only guy i have seen do it cut our a piece of steel that was about a inch thick and fit in ther perfectly he then welding it in place went through about a whole spool of my wire but hes running 40s on a tj and its not broke yet. he just got back from harlen ky and did not have any probs

 

[finn188]

sounds good. im curious to see how long it will last; with all the different opinions out there and what not. like i said, i will post updates so if you want results just subscribe to this thread. thanks for the help.

 

[finn188]

BTW im running 35s, d30 in the front with alloy axles and an ausssie locker. I think I already mentioned it but the rear is 27s 8.25 with stock axles.

 

[IslanderXJ]

i've also heard of people cutting bolts into wedges and using them as filler material between the gear teeth that aren't meshed together for more metal to weld to/with. if it's just a temp deal, i don't know if it's worth the effort or not for that. good luck and throw a pic up when you're done! side note: funniest weld job i ever saw - a lunchbox locker welded in... don't ask.

Had a guy in our club by a rear axle that somebody did that in, except he didn't weld anything just put bolts in!
We were at the Rubicon and heard a loud pop/crack sound and we all though his diff was toast. turns out it just went back to being open!

Incredibly off topic i know....

 

[asp]

Had a guy in our club by a rear axle that somebody did that in, except he didn't weld anything just put bolts in!
We were at the Rubicon and heard a loud pop/crack sound and we all though his diff was toast. turns out it just went back to being open!

Incredibly off topic i know....

holy crap.