DIFF in pajero cracking

It's common for the weld around the axle housing below the spring seat to fail on coil models 88 on, usually a result of heavy loads and rough roads. Don't know about the diff cracking though.

I met a bloke once in Alice Springs. He wanted some info on a certain track which I gave him but insisted that he take care as there were a few bad washouts. He ignored my advice and was sitting on 80kmh on the track in a '90 Pajero. He hit the washout at that speed but could find nothing wrong afterwards. About 100km further on just past Kings Canyon, the whole axle housing came away from the rear diff. It snapped off. Oh what a mess. He wasnt a Happy Chappy and was stranded there for a couple of days. Also cost a pretty penny to get back to the Alice.

Mine gave way completely, 90 Model pajero. I ended up stuck in the middle of the simpson desert for 7 days, quite an ordeal.

Michael from North Shore Four Wheel Drive has seen quite a few come through his workshop. He sent phots etc to Mitsubishi at the time but they never acknowledged any problem.

Mine wasnt overloaded but I did have a long range tank and this probably contributed to the problem.

They can be reinforced, Michael mentioned laminating.

Cheers

Allaussie,
For what it's worth I doubt it will be the actual weld cracking it will more than likely be the heat effected zone adjacent to where the weld is. Using the correct preheat if necessary, the right amps and the correct consumables are critical to getting a good strong weld, ainch of six mm fillet weld is good for lifting a tonne. There is something wrong with one of the three things mentioned above for the welds to be failing like they are. Just my opinion forumites, your may vary.