Thread: cracked housing

Before you weld it drill a small hole right at the end of the crack, It will stop the crack from going further and take the filler plug out before you weld.
Hodgo

Just weld it.

Replace the front housing, trailing arms, ..... with that of a Series1 Disco. Ask around first but I know it has been done without much drama. Lots of Series 1 Disco parts around - (not from us though)

Erich

Mine has cracked around the weld on the pan over the diff centre. I was told that diff casings often crack on Isuzu engined vehicles and that a lot of people have had them strengthened. I am currently stripping a spare front end and will be getting the casing externally strengthened (as opposed to internally laminated/tubed). It won't cost much and will give more strength and protection off road.

As Dave says , quite common problem due to the weight of the engine etc. I would definately do as Erich suggests, a D1/ defender 7 bolt flange housing is the best way to go in the long term, short term , a decent run of MIG weld will prevent it getting much worse. It is preferrable to vee out where the crack is a little prior to welding IE die grinder out along the crack to a few mm of depth to provide a 'gutter' to fill with the bead of weld.

JC

In my view, one contributor to the cracking is the use of more rigid polyurethane bushes which put more twisting force on the axle housing than rubber ones do. Of course, the heavier engine helps as well (I have had cracking round the pan on the front).

John

Originally Posted by justinc

As Dave says , quite common problem due to the weight of the engine etc. I would definately do as Erich suggests, a D1/ defender 7 bolt flange housing is the best way to go in the long term

JC

Hi JC re the 7 bolt flange housing,the housing I have now has 7 bolts that hold the swivel to the diff housing,does that mean I just get a defender housing and use my diff centre,axles,cv,s and swivels to the defender housing?Are the defender housings stronger?Thanks jim.

Originally Posted by yt110

Hi JC re the 7 bolt flange housing,the housing I have now has 7 bolts that hold the swivel to the diff housing,does that mean I just get a defender housing and use my diff centre,axles,cv,s and swivels to the defender housing?Are the defender housings stronger?Thanks jim.

Ah, yours must be late '85 onward then. There isn't anything stronger available then AFAIK, A later model housing would be a better bet due to a lack of fatigue issues etc though.

JC