Need some welding & help

[mayhem]

I am in a bit of a quandary right now and I was wondering if any Denver area TTORA members can help me out.

I need to replace my front and rear gears after a recent trip to Moab... So here is the deal, pulling gears is out of my area and I do have somebody to help me but could always use somebody with additional experience. Furthermore, I have one of the studs in my rear diff stripped and spinning (no it won't come out). So I need somebody who has a 110 portable welder that can spot weld it in place. This stud is the source of a constant leak in my diff and if I am going to be taking gears out I want it fixed.

I am thinking about starting on the truck Friday morning 11/21 and it should be in pieces for more than a few days. It will take more time to plug the welder in than to weld what I need welded.

[thefatkid]

You can borrow my welder if needed. I work friday so I cant come over to zap it for you.

[ike]

If it is still apart on Monday I could possibly bring the POS harbor freight welder down. If you only need a spot weld it should do the trick, but there are no garuntees.

[mayhem]

yeah it will still be apart on Monday... Fatkid, if I had another set of wheels I would come get it...

[Lysmachia]

I gotta take my kis sister to the airport on Sunday. If Troy is up for it we could come by early (Like 8:30) and see what we can do. I need to ask troy though ;)

[mrdoug]

Sounds like he only has 110 available, isn't troy's welder 220?

I know mine is (which is why I haven't offered)

[Lysmachia]

Oh crap. Yes it is. Mayhem if you have a stove or dryer nearby we could help.... PM me you phone number because I don't have it.

[ike]

Let me know if you still need help on Monday afternoon. I can likely swing by with the 110. Depending on how it is broken though i dont know if we will be able to tac it to fix it. Does the weld have to be on the sealing surface? if so it may be hard to do and still get a seal out of the rear.

[Lysmachia]

Ike can you get me the 110 before Late sat, we could take that sunday? Just trying to help how we can all!

[mayhem]

I'm going to wench Saturday with a friend. But it will be in pieces for the week... I'll be at his garage so I don't know about getting 220 nearby.

[00regcab]

Sorry to hear Eric, I might be able to swing by and lend a helping hand (as i've had both diff's out, without much of an issue).


Hope all goes well, what are you going to re-gear to?

[mrdoug]

Does the weld have to be on the sealing surface? if so it may be hard to do and still get a seal out of the rear.

Yeah, I have to wonder how it's going to get tacked in... if the stud is spinning, tacking on the outside will surely effect the sealing of the third, tacking on the inside will be a serious challenge to get the gun to.

[ike]

Molly, i will not be down your way until monday, but if you want to swing up to Dougs you are welcome to borrow it.

[chilitoy]

I have a 110 wire feed and I live in the Wash Park area. Where are you in Denver. I could probably swing by if you still need. I agree with mrdoug on the weld and leak issue. But if we weld and grind it flush(carefully) it should be o.k.. Let me know.

[mayhem]

chilitoy, I'll be at my buddies garage out near Stapleton... Yeah it's going to be surgical, but I think I can swing it///

[ike]

RTV will be your freind.

[RedRunnertc]

You could always countersink the back side of the hole a little to give you some clearance for the weld.

[ike]

Good idea

[Lysmachia]

Mayhem you never PM'd me your number... ;)

[mayhem]

Sorry. molly... I got it on my phone and the reply didn't go through... PM'd you. I got both diffs out and the studd welded thanks to chilitoy....

[ike]

Good to hear man. Let us know if you run into any other problems.

[mayhem]

You mean problems like this:
http://www.sukcess.com/links/diff_chew.jpg

[thefatkid]

Looks like you broke them going in reverse. Do you remember any situations like that? Could be due to pinion preload loss.

[ike]

would the pinion loose preload if the driveshaft got droped on something?

[mayhem]

I remember a lot of "Situations" :P

I think it was literally the last obsticle of the last day when it all happened...

[ike]

Yeah, that was a tough ledge! And you didnt have the vibration until the very end of the day.

[thefatkid]

would the pinion loose preload if the driveshaft got droped on something?

I wouldn't think so, though the stress of wheeling who really knows.

The reason I belive it happened while backing is the "chaffing" on the carrier from the pinion head. The Pinion seems to walk in the carrier durring "harsh" reverse manuvers. If you look at the way the pinion contacts you can see if it was forward (drive side of the gear) it would have broken the "toe" off of the right most broken gear. If you notice the broken gear is about the total contact of the pinion on that gear indicating a impact failure more then a rotational gear failure. If the gears/bearings would have worn and failed because they were too loose you would expect to have seen more teeth in a row fail. Your total gear contact durring any given rotational period seems to be 1 full tooth and 2 halves.

[00regcab]

I wouldn't think so, though the stress of wheeling who really knows.

The reason I belive it happened while backing is the "chaffing" on the carrier from the pinion head. The Pinion seems to walk in the carrier durring "harsh" reverse manuvers. If you look at the way the pinion contacts you can see if it was forward (drive side of the gear) it would have broken the "toe" off of the right most broken gear. If you notice the broken gear is about the total contact of the pinion on that gear indicating a impact failure more then a rotational gear failure. If the gears/bearings would have worn and failed because they were too loose you would expect to have seen more teeth in a row fail. Your total gear contact durring any given rotational period seems to be 1 full tooth and 2 halves.

Deja-vu!

My diff looked similar, only mine was 3 teeth in two separate spots on the ring gear.

I must of missed any issues you had with the "last ledge" on steel bender? Either way, at least you've got the problem diagnosed and you'll be able to get it fixed fairly easily.

You said you were planning to re-gear? What ratio are you thinking of going to? Are you going to throw a locker up front while you're at it?

Let us know how it goes!

[Volcom]

Nice work! I can't believe you drove back to CO on that diff!

[mayhem]

4.88's and I'm not doing a front locker... it might be worth my while but financially this is killing me.

[ScottyC]

4.88's and I'm not doing a front locker... it might be worth my while but financially this is killing me.

Well, I got Eric all squared away today with the new rear 3rd. Took me a while to get the 3rd setup, but he's good to go now. :welder:

[Lysmachia]

Yes! Thanks Scotty!

[mayhem]

Rear is installed, waiting on part for the front. Thanks for your help Scotty... I owe ya.