Welding rear axles to drive flanges

[robdav]

Had my rear axles on my 130 welded to the drive flanges on a recent overland trip through Africa as the lateral movement of the axles on the bad roads kept knocking the dust caps off. I later sourced some larger dust caps of an earlier model that would have solved the problem.
Anyway, now that we are back in OZ what are the possible negatives of leaving the welded ones in place or should I buy some new axles and drive flanges.

[Jock The Rock]

Had a mate who bought a defender with a similar thing done

It was all good until the weld cracked and finally broke and diff oil started leaking out. (He had oil immersed rear bearings)

If I were you I'd be looking at getting yourself a set of these or something similar

Ashcroft Transmissions - 5806 (http://www.ashcroft-transmissions.co.uk/index.php?act=viewProd&productId=60)

[cewilson]

It's about $100 per drive flange to get the heavy duty drive flange and screw on cap from Rover Parts. Well worth the money and fixes the problem for good.


In other words $400 for the upgrade for the whole vehicle.


Cheers
Chris

[oldyella 76]

I welded mine with a mig and normal wire. I made a jig to keep it true between the axle and the drive flange. I then placed it in the lathe, between centres and machined the flange true to the axle to stop flexing. Been Canning twice Gulf and for four years of trips have not had any problems or cracked welds. Have the jig if anyone wants a loan.

[Trout]

My cousin is a welder and he has welded his a few times. They ended up breaking so I figure it is probably not the best idea long term. The hd flanges add a bit of bling anyway :cool:

[Didge]

My understanding is that it will transfer the load to your diff(s) which will cost a lot more if the damage occurs there, but given oldyella's recordit could be worth considering :)

[Jeff]

I had a 2A once where the axles were welded. The weld cracked but luckily there was an uneven break and it still had drive, but lots of slack while driving. I replaced them as soon as I could.

Jeff

:rocket:

[mark2]

As an experiment, I welded mine about 12 months ago with no problems so far. It was supposed to be a temporary measure until I could afford some Hytuff axles and flanges but those plans are now on hold.
Welded the outside of the flange only so if the weld breaks or the axle breaks at the weld, it will still have drive through the splines.
I used a mig at a fairly hot setting and preheated the ends of the axle/flange.