Welding the Diff

[luigi]

Does anyone have any information on the best way to weld the differential? Mine broke after a few runs, any info is appreciated. Maybe someone has some pics?

[Rudezuk]

Try this instead of welding... http://www.differentials.com/producti.html

[ 08-17-2001: Message edited by: RudeZuk ]

[luigi]

Thanks Rudezuke, but this winter Toyota axles are going under so I don't want to spend much on these axles. I just need to get by for some more summer wheeling....

[fatkid]

Weld it! Come awnn! <IMG SRC="smilies/skull.gif" border="0">

[poppycock]

"the bigger the glob the better the job" is how it was put to me <IMG SRC="smilies/biggrin.gif" border="0">

[luigi]

Is a Mig welder ok to use, or should it be stick..

[Hayraker]

STICK!

[fatkid]

STICK of butter?

[webilt]

JB Weld it,,, come awnnn... <IMG SRC="smilies/biggrin.gif" border="0">

[Vermin]

I welded the diff for my friends Sami, and he broke it driving on the street a few days later. I felt pretty bad about it.. until he broke it loose again after having a pro do it the second time. He's on his third weld job now.. and its held together through some fairly serious wheelin (about 8 months worth).. So Im not sure what the trick is.. just weld it.. ALOT.. gears to gears.. gears to housing.. fill the damn thing with a big ass puddle of welding love!!

Rob

[ROCKILLER]

I welded mine with a mig but you have to have a powerful one. none of that 110 crap. Go for it. Weld as continuously as possible to really keep the heat up.

[DougO]

well, with my rear, I welded the side and spiders together outside of the carrier making sure it all was solidly welded together and consistantly. But since it wont fit in then I ground the outside down until it slipped in, looks kinda like a mini-spool now <IMG SRC="smilies/bounce2.gif" border="0"> . Dont have to worry bout the thrust washers anymore anyway since nothing is gonna spin. <IMG SRC="smilies/smile.gif" border="0">

[fatkid]

Anyone try the Stick of Butter method?

[skeetshooter]

yea I used "I cant believe its not butter" havent noticed any off road performance improvement.

[x2_rage]

I'm a toyota guy, and I don't know why I am here . .but just pokin around. I have welded on my diff a few times and this is what I do:
Slide the axle shafts out a bit, and remove the 3rd member. Run 6013 rods, and run low amps. Grab a wire brush and clean off the surface like never before. I even use a grease remover to make sure nothing is going to screw with the arc. Then I run a low amp bead along the weld. Its pretty darn easy to poke a hole in them, and that can be a bitch to fix. Once you have a layer of welds there, let it cool, and crank up the amps. Run another pass with more amperage. I usually run between 65-85 amps on the first pass, and then go up to 110-115 for the next few. Sometimes I even do somepasses with a 6011 to cross thread the layers of welds, but I'm anal.

[x2_rage]

OOP! Your not talking aboutthe housing, you are talking about welding the 3rd member, aren't yah? In that case, use 6011 rods, ~90 amps and go to town. Cover them up with 6013 and grind them down clean. DO a few passes. Simple shit.

[hy_desert_4wheeler]

I have welded several rear diffs using my MIG which is a miller185. when i weld them I weld the spider gears where they meet the one next to them. make sure you get good penetration and fill up the teeth on the gears( not all the teeth just the two or three on either side of contact) in each area then rotate the diff and weld the other side. you should break the axles before the welds let go at least that has been my expirence. <IMG SRC="smilies/jeep1.gif" border="0"> <IMG SRC="smilies/jeep1.gif" border="0"> <IMG SRC="smilies/jeep1.gif" border="0"> <IMG SRC="smilies/jeep1.gif" border="0">

[ZUK]

I welded up a Yota IFS front member just like hy_desert_4wheeler did.....I also used my Millermatic 185 MIG for the job and used it on "low amps" also. I figured the same thing as Russ did....weld the teeth together where the sidegears meet the spiders for a total of 8 welds....they will not be the weak link. If all I had was a Lincoln 100 MIG to weld with then that would be no prob for me again.

[ 08-28-2001: Message edited by: ZUK ]

[komatzuk44]

I couldn't wheel the same without a welded or spooled diff, Limited slips just aren't locked, lockers(not talking about fancy selectable types) I don't trust cause they unlock( should be called un-lockers stead of lockers) sometimes which throws a shock to the driveline(I've seen more locker equipped axles snap than welded diffs, but the welded diffs seem to loosen the pinion shaft up quicker) and therefore causes inconsistent handling with the slip up which most of them time you never notice it off road,but in certain conditons wheeling fast on hard dirt roads it messes up your back-pedal traction effect which is how I hold a line through a lot of turns off road, I love to drift(keeps from tipping if yer skiddin) around fast where I can and the samuri is the only street legal atv that does it high thrill like (just neeed more power). The security of having both tires welded or spooled helps at holding the groove. At first driving with either takes a change in habits and predicting where you go, all I'm saying is stick with the spool/welded diff(seen only cheaper mig ones break) I've found it to be less spooky and lets really look at the benefits of a few moving parts the locker offers as opposed to a solid piece to hold the ring gear and axles-Tire wear- how much do you save on wear from an offroad vehicle that skids the tire through the turn completely as opposed to skidding most of it with a couple unlocks to chirpy chirp things up, that unlocking is annoying to me and the banging makes me cringe evrytime not too mention the steering effect on the street is more eratic(fun in the rain), some say the wind up a spool has on an axle causes it to break easier on the street opposed to the relief the locker gives- in a heavier vehicle this holds true which is why not too many people run spools on the street but the sammy is so light it doesn't seem to matter, the locker releases very crude and the sammy doesn't have the weight to calm the forces, just my experience on the subject- my nickels worth, call me crazy cooter but when I ain't wheeling I'm thinkin bout all them purdy hikin chicks I'm missing out on with thier Lara Croft fantasies they be havin wit each other on the mountain. Stay Zooked people.

[UZI 9mm]

:confused: WTF was that?


jeezuz.

[billj]

Tuff enuff read that I didn't even try...........

Holyfawkingrunonsentancebatman...........

[rocatx]

I welded mine 3 years ago 110 mig broke rear after 2.5 years front still holding up just fine

[zukiester1]

This has been covered on here like a beatles song. But I know the search is not working huh? Weld the gears together, then fill up that side of the case, then go to the other side, same deal. Don't get it too hot or you will warp the carrier. I welded mine and my old man's up with a 220 Snap On over three years ago, no prob's. Well I did get his too hot and warped the housing a little. Only way to go in a sami.

FWIW


Jerod

[baldur]

Air lockers are so much superior to welded differentials. Selectable between completely solid and completely open.

[zukiester1]

Yea but only 598 dollars more :flipoff2:

[SJ410Rocker]

I have welded six or seven thirds now. I wedge bolts into the spider gears so the diff is locked already. Then I weld them with 7018 rods 1/8" for more fill. I just melt the bolts into the spider gears and carrier housing. You will not break it this way.

I dislike air lockers, a friend of mine has them and sometimes they get stuck. There are also alot of extra bull shit involved with those, alot of different parts to fail. With a welded diff there is just that and it has a very predictable response. Welding them with bolts you will break an axle or ring gear easier than the carrier.

[brian d]

i welded up my ford 9" in my jeep with a 110 cambell hausfeld welder//i welded all the gaps closed except where the teeth mesh//(the 9 has 4 spiders & 2 side gears)
been running for about 9 months with 35x14.50 swampies//

[SOBX2380]

Just out of curiosity....A lot of you guys in the above posts are stick welding your diffs. Is there any reason? I have a TIG and MIG at my shop.I rarely stick weld anything because the MIG is more convenient. Is there some benefit to stick welding a diff? Or are the guys who spoke up about stick welding it because thats what they have available?

[Islandzuki]

I couldn't wheel the same without a welded or spooled diff, Limited slips just aren't locked, lockers(not talking about fancy selectable types) I don't trust cause they unlock( should be called un-lockers stead of lockers) sometimes which throws a shock to the driveline(I've seen more locker equipped axles snap than welded diffs, but the welded diffs seem to loosen the pinion shaft up quicker) and therefore causes inconsistent handling with the slip up which most of them time you never notice it off road,but in certain conditons wheeling fast on hard dirt roads it messes up your back-pedal traction effect which is how I hold a line through a lot of turns off road, I love to drift(keeps from tipping if yer skiddin) around fast where I can and the samuri is the only street legal atv that does it high thrill like (just neeed more power). The security of having both tires welded or spooled helps at holding the groove. At first driving with either takes a change in habits and predicting where you go, all I'm saying is stick with the spool/welded diff(seen only cheaper mig ones break) I've found it to be less spooky and lets really look at the benefits of a few moving parts the locker offers as opposed to a solid piece to hold the ring gear and axles-Tire wear- how much do you save on wear from an offroad vehicle that skids the tire through the turn completely as opposed to skidding most of it with a couple unlocks to chirpy chirp things up, that unlocking is annoying to me and the banging makes me cringe evrytime not too mention the steering effect on the street is more eratic(fun in the rain), some say the wind up a spool has on an axle causes it to break easier on the street opposed to the relief the locker gives- in a heavier vehicle this holds true which is why not too many people run spools on the street but the sammy is so light it doesn't seem to matter, the locker releases very crude and the sammy doesn't have the weight to calm the forces, just my experience on the subject- my nickels worth, call me crazy cooter but when I ain't wheeling I'm thinkin bout all them purdy hikin chicks I'm missing out on with thier Lara Croft fantasies they be havin wit each other on the mountain. Stay Zooked people.

whacha talkin bout Willis???? :flipoff2:

[SJ410Rocker]

I use stick because my wire feed is a 110v which isn't good for anything over 1/8". When I weld the diff I like to make a good puddle of everything inside there. I have also heard that with stick is better to use a stainless steel rod to weld the gears.

There is nothing wrong with using mig or tig. I think they would be better since there is no slag clean up.

[zukman27]

I tried that three times and it failed 3 times I just tried easy stuff and still broke axles at idle Whats the secret? 88 ZUK 1.6 8V 4.16 5.12 35 GRABBER MT

[Islandzuki]

I tried that three times and it failed 3 times I just tried easy stuff and still broke axles at idle Whats the secret? 88 ZUK 1.6 8V 4.16 5.12 35 GRABBER MT

weld it right :grinpimp: I think if it is properly welded it would be real hard to fail..........

[zukman27]

the front axles keep breaking off at splines

[zukman27]

any one in sw pa want to take a falls run

[Islandzuki]

the front axles keep breaking off at splines
OK then thats a easy one........get bigger axles :flipoff2:

[EHeye]

I have just my rear end welded up (sj413), the first time we welded just the spider gears and that eventually broke all the teef and made a inch of metal slurry in the bottom of my housing. I took it to a guy that does this stuff all the time and he took out the spidergears completely and welded with stick right around searing the two together rather than the spider gears. Works good, cept for losing tires and shit from turning (daily driver).

[Orionn]

I run the rear 'Fozzy Locked', (welded side gears so you get a few degrees of turn befor they lock)
been like that for over 3 years, no problems.

Mig welded and dressed with a grinder. :D

[zukman27]

I am going to get a set of yotta axles saturday so i can run locked front but gonna hate my yotta budies telling me it only goes so good cause it has yotta axles any help for that

[SJ410Rocker]

We ran a samurai front axle welded on 35's and never had problems. We did have the birfield rings.

[zukman27]

I ran welded front with 33s and 512s with stock t case but started breaking splines off axles once I ADDED 416 kit

[SJ410Rocker]

I am going to get a set of yotta axles saturday so i can run locked front but gonna hate my yotta budies telling me it only goes so good cause it has yotta axles any help for that


Use Dana axles then. That way you can say who needs that Yota crap.