Welding a broken front diff housing?

[Brett H]

Hi Folks

I've just encountered this exact problem:

http://www.expeditionportal.com/forum/t ... ff-housing

I'm currently in Zambia in Lusaka, we've managed to limp our way here after some dodgy welding to stopp the diff oil leaking and now looking for a proper repair.

What I'm wondering is if there are any welding specifications or procedures anyone can point me towards for re-attaching the bracket onto the diff housing. I haven't had any experience with welding onto cast iron before and want to ensure these guys repair it properly.

Any feedback welcomed.

Cheers

Brett

 

[Cptsideways]

I'd suggest to heat the area up before local welding, I'm not sure if its a casting (I did'nt think it was) You could also add some extra plating for good measure.


Best of luck with it

 

[Andrew Prince]

Not unheard of with SFA cruisers (80s and 105s) with caster correction bushes. I believe that the axle can be successfully welded without too many issues - probably worth added some bracing/gussets and strenghtening the other side while you're at it.

Obviously be careful of the inner axle oil seal if you're doing a lot of welding in that area or next thing you'll have the diff oil doing nasty things with the moly grease around the CV and adding to your list of things to do

While no-one likes to see their axle cracking, there haven't been many stories of catastrophic failure (I'm not aware of any) so I believe that these cracks are more related to fatigue due to the twisting of the axle (relative to standard) due to the CC bushes. Some judicious welding and you'll be fine!

 

[Paul_Humphreys]

Never done a LC but done lots of Land Rovers. Just set the welder up a little higher. Easer to do with the axle off and with an arc welder. Just make sure it is oil free and clean (brake cleaner) before welding.

Paul

 

[Paul]

There used to be a method we used on cast parts.

Full strip down because of the heat. Area is heated cherry red with gas and then stick welded (while hot) with the correct rods, then the item was buried in sand to slow the cooling process. Have done engine blocks and various cast earth moving equipment accessories this way.

 

[Chris]

That's not cast.

The radius arm itself maybe, or possibly a forging, but the diff and brackets aren't. The front axle is a patchwork of welded steel sections. You're unlikely to put that much heat into that with welding especially if you do short runs and cool it off in between. If you warm it too much then weld it, it will expand and then shrink when cooling possibly leading to more cracking. Don't quench whilst it glowing. But get it coolish before going again. If it were cast, then sure treat it gently, but pretty sure it's not. I worked in foundries for years and we didn't cast axles in iron. Some lorry axles were cast in steel but that's a different game. Way too tricky.Do watch out for fires. Good idea. If you are using MIG then make sure it's polished up and that the gap is clean. Mig can be built up in layers rather then try to dollop loads on in one go.. If possible vee it a little, weld, grind back and then over plate if necessary.

Chris

 

[Toby]

I'm with Declan on this one; the front axle casing isn't a casting, it should be fine with gas or mig welding. As Andrew says this isn't unheard of when using caster correction bushes and using lots of front suspension travel...

Best of luck,
Toby
1990 HDJ80
1994 HDJ80

 

[Brett H]

Hi guys,

Cheers for all the responses. Very useful. Turns out they are going to remove the whole axle to weld it. They are planning on arc welding it using stainless 312 rods. Any ideas on this? Do you think its a good filler material?

Cheers
Brett

 

[Chris]

Stainless? No use 6013 standard mild steel. 2.5 or 3.2 mm

Chris

 

[Andrew Prince]

They are planning on arc welding it using stainless 312 rods. Any ideas on this? Do you think its a good filler material?

Hell no As Chris said, they need to match the material fairly closely.

 

[Dave Docwra]

hi, Stainless steel rods not needed, Foleys the land rover specialists have a place just before the falls in Livingstone, if you can make it to them, I am sure they would be able to do a good job to your 80. Did the endless bitch of the Moyale road contribute to the crack?

Dave.

 

[Brett H]

Hi guys

Sorry for the slow response on this, just wanted to get a thank you note in to everyone that responded to this post. Great to have a sounding board you can rely on there when you're being fed a range of tall stories at this end.

I ended up tracking down a replacement housing and using that after losing faith in yet another African welding attempt.

Will have to do some research on these bushes, don't want this happening again!

Thanks again

Brett