75 series diff housing

Depends on where and how big the split is, giving it a quick zap will do for temp roadside repairs but it really needs to be cleaned and welded properly.

hey mate, drain the oil, clean the area, grind it smooth if you have to and fill if you have to then weld a run above and below the crack, clean the welds, then bump the power up slightly and use a slighlt bigger rod, and weld a clean run through the guts, should be able the hand 3 tonne off the weld......(if you wanted too), bu nothing will get through the pal, let me know how you go!!!

Sparra,

I had the exact same problem.

Tried to weld the crack on the vehicle, but the crack opened up again.

Took the diff housing out of the vehicle, ground the crack, drilled the end of the crack to stop it getting any bigger and welded a plate over the crack. Replaced the diff and no more leaks, however the other side if the diff housing cracked after doing the Canning and the Kimberleys.

I fixed one crack and another appeared. I could have plated the new crack but where will it end.

I finally ended up getting another second hand diff housing that has not been cracked and put that in.

Why I think that they crack is if the vehicle is jacked up with the jack under the centre of the diff, too much weight is put on to the outer ends of the diff housing and the diff housing bends slightly and then cracks.

The 78 Series that I have now has the reinforced diff housing, the 80 Series was the same but I don't know why they did not reinforce the 75 Series diff housing.

If you want to weld the diff housing and only have to do it once, take the diff housing out and weld plates over the cracks. It might take the best part of a day to but in the long run it will save time.

Wayne

Sparra, Welding diffs insitu is generally fine ,just make sure the crack is clean of any oil or dirt (wire brush and petrol, if the oil level is crack high you may have to to empty a bit out). I use WIA 16 TC welding rods as they will take to most steel surfaces.

I have found the ones that we have welded up havent lasted including on my own car I enned up getting a new rear diff housing in the 79series but its no majoer drama having a crack in the diff housing I drov 9000kms to broome from weipa with mine cracked.