step 1: drain oil, remove cover plate
step 2: degrease (lots), rinse with water
step 3: use metholated spirits to remove residue around weld area, fill diff with water (reduces chance of fire and splatter sticking to gears underneath) and let weld area dry again
step 4: insert 2 appropriatley sized bolts, preferably high tensile carbon steel bolts (aquired from bunnings, the black ones)
step 5: turn welder up nice and high, start welding all the teeth together and to the bolts, fill out to flush with bolts, taking care not to arc on gears, also set welder to minimize splatter.
step 6: rotate gears to exspose opposite side of spider gears and repeat steps 3, 4 and 5
step 7: drain water. remove any splatter on visible gears using sand paper/fine file. Reseal, fill with oil, install into car.
NOTE: WHEN INSTALLING, ENSURE CV'S ARE ALIGNED CORRECTLY. LEAVE DRIVERS SIDE CV OUT, REMOVE FROM VEHICLE COMPLETELY (THIS IS EASY TO INSTALL LATER)
bolts in place ready to weld
welded out to flush of the bolts, plenty of grab between teeth
picture of internal set up showing weld area (diff is upside down on the table)
TO INSTALL DRIVERS SIDE CV (REQUIRE JACK, HAMMER, PIN PUNCH AND ROLL PINS) AND LOCK REAR END, JACK UP REAR DRIVERS SIDE TILL WHEEL IS FREE SPINNING, THIS WILL PROVIDE ENOUGH SPACE BETWEEN DIFF STUFF AND WHEEL STUB TO INSERT SHAFT, ONCE AGAIN YOU WILL NEED TO ENSURE CORRECT ALIGNMENT OF THE SPLINES. ONCE IN POSITION, LOWER VEHICLE
FINISHED
.....i made that mistake
