Thread: Front diff housing crack

I had a crack appear around the weld where the diff cover meets the banjo housing, on the front diff of my 88 Range Rover after extended periods on severe currugations. Not a huge issue as it is not a load-bearing area. I ground it back a little and applied a bead of weld with the housing insitu and no further problem there.

Originally Posted by POD

I had a crack appear around the weld where the diff cover meets the banjo housing, on the front diff of my 88 Range Rover after extended periods on severe currugations. Not a huge issue as it is not a load-bearing area. I ground it back a little and applied a bead of weld with the housing insitu and no further problem there.

Similar on my County. I think the corrugations on the Cape York trip last year were probably what did it. Thankfully only about 1" long at the 1 o'clock position looking aft, and just leaking enough to be annoying.
I vee'd it out a bit with the grinder and hit it with the stick welder - all good now.

Steve

It is very common for front housings in Isuzu landies to bend if the vehicle is used offroad. Could the crack be a symptom of stresses caused by a bent housing?

Originally Posted by POD

<snip> Not a huge issue as it is not a load-bearing area.

If it wasn't load bearing it would not crack, I would say it certainly does have stresses on it.

I had the same issue with a 2 door Range Rover in the 1980s
I cracked both front and rear housings this happened after continuous corrugated roads at speed.

Yup,

I have a weeping front housing, but it has a welded on diff guard, so not sure if it's just weld porosity or an actual crack. I ground it back and rewelded, but its still weeping. I used a gas MIG to weld it, and later found out that stick (or gasless MIG) is apparently the way to go - the flux is supposed to prevent oil affecting weld quality.

After rewelding 3 years ago:


1 hour ago:


I only lose a few drops a week, so not overly concerned, but plan to take off, clean and reweld properly in the near future.

I'm only running a 1992 RRC 7 bolt front housing in mine, (Same as County except RRC / later defender swivels, ) but have a narrowed ex Perentie 6x6 one to go in at some point to avoid this happening. I don't hammer mine anymore offroad, but later will be seeing lots of corrugations etc so a safe bet is to fit this housing and forget about it

JC

Originally Posted by justinc

I'm only running a 1992 RRC 7 bolt front housing in mine, (Same as County except RRC / later defender swivels, ) but have a narrowed ex Perentie 6x6 one to go in at some point to avoid this happening. I don't hammer mine anymore offroad, but later will be seeing lots of corrugations etc so a safe bet is to fit this housing and forget about it

JC

is that the housing with the cast center section and pressed in tubes?? If so You may now be scared of pulling tubes if you read the Sals thread......I think your in trouble JC