Welding Diffs

[grand_wag_85]

I've done some searching and I haven't found much on the subject so I figured I'd ask.

I'm planning on welding the diffs on the J10 and maybe the XJ so what all is involved? Does the carrier have to be pulled?

[grand_wag_85]

Whoops, probably shoulda put this one in the Off Road Tech section, my bad...

[Crazy_Jeepman]

I Weld them up in the axle. Get some brake cleaner and get the gear oil off the spider gears. ;)

[grand_wag_85]

Thanks crazy Jeepman. Hopefully this will help w/the J10's Mudphobia.

On a different note what are your thoughts on welding a D30? All the XJ guys I've talked to say don't do it but I don't see what the big deal is. I know I've pushed it way beyond what it's designed for from time to time but if the diff was welded I wouldn't have needed to, ya kno?

[Crazy_Jeepman]

I can honestly say.........I do not recall ever looking at a D30...........mostly D44's Dana 60 and 14 bolt

[orangecherokee]

for the D30 I only know of one guy that welded his. he never mentioned anything special but I didn't really ask either. I know the D35 have C-clips and you might have problems removing the clips but for the D30 I have no clue making this a sweet PAD. :D

[grand_wag_85]

Well there's only one way to find out, run it 'till it breaks and see what happens :D Thanks for the help, again

[Crazy_Jeepman]

I have no clue making this a sweet PAD. :D

Could just go to the Diff Cover thread and ask for Installed Pics..........ROTFLMAO!! :thumbsup:

I agree though I do not see what the issue would be outside of maybe the axle shafts are to scrawny to take the unforgiving twist when taking corners, ect.

[rustywagoneers_com]

it can be helpful to get some heavy duty aluminum foil and cover the ring gear / etc to help shield stuff from slag-balls... it worked for me!, had to do 2 layers of foil though, and it still burns through some, but it makes it less likely to have slag stuck to the gears...

peace
Dave

[Desert Beast]

foil can work,
i use this spray, (called splater shield or something like that) and just spray it on everything and you will just be able to wipe off any boogers. works great for all kinds of welding where you dont want to get boogers on other stuff.

[scotty]

i personally like to pull diffs when welding them,and remove the ring gear. i weld much better standing over my workbench than i do hunched over,underneath a gas tank,and how good a job you do directly affects how long it will last.

the important thing,however you do it, is to make it one big solid chunk. weld the gears where they touch on both sides,and weld all 4 gears to the carrier,both sides. welding just the gears,or filling in teeth tp prevent spinning can cause the gears to shatter,or the cross shaft break,leting the outside of the diff spin helplessly around the welded gears :eek: . good welds in the right places will make it as strong as a full spool,IMO. dont worry about "ruining" the carrier if you want to go back to open. open high carriers are a dime a dozen,and even the open low(4.10+) carriers are available new.

on welding the front 30,depends on the tire size and u joints. 260x sized joints are more likely to break than the 297s with a welded diff,especially if tires are in the 31 inch+ size. if you have a disco front 30 rig it to its own vaccum switch sos you can flip the one side off for easier steering. keep it locked the rest of the time,tho,as driveing with only 1 front wheel pulling puts alot more stress on that axleshaft,making it twice as likely to break than if both fronts were pulling ;).

welding a rear 35 will result in breakage with 33" or bigger tires(or any size bogger :D ),so make sure you have some spare sahfts. a friend of mine ran a 258/t18 in an xj and broke 35 shafts all the time with a welded diff and 31" boggers. another friend ran a welded 35 with a stock 2.5 4 cyl and 4 speed,and 33" mud tires. he broke rear shafts also,but not as often ;)

further diff welding questions? :drivin:

[grand_wag_85]

Sounds like a great time for the D44 swap now but looks like I will be upgrading to the 297X U Joints.

[FSJeep80]

I usually weld them with the carrier in the rear. Don`t be skimpy and make sure you use enough heat to get good penetration. I love welded rears offroad but I wouldn`t use one for the street. Turning on high traction surfaces is really hard on the axles.
Your XJ should have a hi pinion 30 in it which actually aren`t too bad. Does yours have antilock brakes? The ones that did had beefier axles and bigger U joints. You can retrofit them to non antilock axles. With the little U joints welding the diff may just make a lot of extra work for you (replacing broken U joints). FSJeep80