Hairline crack on diff.

[PeterH]

I have a hairline crack on my rear diff that has been slowly getting worse, can anyone suggest a good welder west of Melbourne who would be up for a job like this?
Doesn't have to be west of Melbourne, but that's where I am.
Cheers, Pete.

[isuzurover]

Where is the crack? Is oil leaking through it?

If it is just in a bracket then anyone can do it. if oil is weeping through it will need to be thoroughly cleaned inside and out and may be easier and cheaper to get a new housing.

[benji]

Is it on the third member, or the diff housing /able tube?

[roverrescue]

If it is just in a bracket then anyone can do it. if oil is weeping through it will need to be thoroughly cleaned inside and out and may be easier and cheaper to get a new housing.

Ben,
Although I technically agree with you and think peparation is more important than the weld itself
I have welded up one and know of many 78/79 series diff housings that get hairline cracks around where the bell welds to the tubes. Die grinder to vee the crack out then using LoHy rods or 316 rods for shrinkage reasons ran a small SMAW bead right down the vee. Works a treat and leaks no more. I would not attempt this if the crack was longer than say 25mm and more structurual in nature but compared to stripping and cleaning it would be worth a shot?? Whats the worse that can happen - it doesnt seal and you are at square one.

S

[PeterH]

It runs in a circle around the main housing and yes oil is leaking through.
I'd like to get this sorted, as it's leaving smelly diff oil on the driveway.
I've kept the oil level up, so there should not be any other internal wear due to low oil level.
Sounds like a tricky repair, not sure which way to go with this one...repair or replace.

[wayneg]

I think a forum member Gippslander has an axle housing for sale

[TheTree]

Hi

Sounds like a replacement is the best option.

Good luck

Steve

[PeterH]

Will have to start looking around for replacement options...quick question, are the diffs from earlier P38's the same as the later models? Mine is a 2001.
Cheers, Pete.

[TheTree]

Hi Mate

According to MicroCat, they early axle casing is FTC426

and after (V) XA 410482; TVI100010 [ when replacing the axle case, the breather pipe adaptor must be renewed ]

So they are different

There are a few P38 wreckers on ebay, might be worth a try.

Steve

[benji]

I wonder if the brake pipe bracketry would be the only difference. (Edit - VA346794 is when the brake pipes changed)

C and d series abs used the same sensors too.

[PeterH]

Just posting a follow up to this thread, I got under there this morning with a drill/wire disc attachment and degreaser, gave the whole area a thorough clean up.
Once it was all clean, I could see a very fine crack running along the upper left side, as well as another crack almost on the bottom, both areas appeared to be along the edge of the original weld.
I took it into an exhaust place near me, the guy there is an excellent welder and he welded it all up for me. Will let you know how it goes...so far it is bone dry, fingers crossed!
As I cleaned it all up myself, they only charged me $25, which was pretty reasonable I thought.