Cracked front diff housing??

[steveG]

Anyone come across cracking in the horizontal weld on the long side of the front diff housing?
I’m familiar with where they crack around the front cover weld, but haven’t struck this before.

https://uploads.tapatalk-cdn.com/20220930/558f9533de8fdb21c40a84d45d56e13e.jpg
https://uploads.tapatalk-cdn.com/20220930/fab128a197c4c9942374e8946b6475d9.jpg
https://uploads.tapatalk-cdn.com/20220930/8d2328b7f396508f868fd8edc4b1e55b.jpg

Steve

[JDNSW]

No, like you I am familiar with the cracking round the front cover. Both this, and what you are seeing, I suggest result from twisting of the housing caused by articulation (one side up, one down) with the bushes at the axle end of the radius arms being stiffer than designed. Probably exacerbated in the Isuzu by the heavier engine.

[steveG]

That’s my view also.
In this case the original cover was also cracked and had previously be welded multiple times.
I’ve replaced the cover with an 8” pipe cap, but only noticed this crack while cleaning the rest up for painting.

I’ve cleaned it up with solvent and then put some penetrant on the inside with the seam facing down.
Will see if that makes its way to the outside overnight so I know if the crack is all the way through.

Steve