Welding rear axle - Potential damage question

[Doobert]

Howdy everyone. I'm looking into replacing the stock Dana 35 rear axle in my '99 XJ with ford 8.8 out of an explorer. I would've preferred to use a Dana 44, but they seem to be impossible to get my hands on, or far outside of my budget. My question is if I risk damaging the internal components (pinion/gears/carrier) if I weld the tubes the the pumpkin, or when I weld the replacement spring perches or shock mounts if the internals remain inside. The axle bearings and seals are easy to replace, and I'll replace them while the axle is sitting in front of me, but I really don't want to play around with the pinion and gears if I don't absolutely have to. Will they have to be removed when I start welding?

 

[Evan03]

I have not damaged gears or bearings from welding often lots of welding.

Weld spider gears to themselves and to case while your at it.

 

[MAY POP]

I also have welded on axle housings without any trouble.

Ron

 

[Rockwood]

Cover everything in pam or spatter spray, then cover what you can in tinfoil.

Or, get a mini-spool.

 

[MAY POP]

It does not appear he is trying to make a Lincoln locker. He wants to weld on brackets to the housing. This is very common and not a problem.

Ron

 

[Doobert]

Yeah, I'm not worried about spatter or any cosmetic blemishes. I was just worried about arc damage to the gears from the welding machine, which doesn't seem to be an issue here. I work on CNC machines for a living, and it is a very real concern there, so I was just wondering if I could get away with it on an axle.

 

[Evan03]

I've heard people worry about arcing bearings but I have never run across that issue at least that I know of in my stuff

 

[Goose_XJ88]

I think the biggest "issue" you have to overcome is the preheat and slow cool of the center section if welding the tubes to the center section.

 

[Evan03]

Use a needle scaller on weld right after welding then wrap in x blanket to cool