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HybridZ

How to weld a 200 diff


stroked_Z

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If done right, it will hold up to a lot of abuse, but if done by someone who has very little welding experience it is going to break very easily.

That's what gives welded differentials such a bad rep.

 

If you don't have the experience, you should take it to a competent shop to have it done.

 

Some quick googling should teach you how to weld up any open diff. Basically you need to remove all of the internals and degrease everything very thoroughly. Any residue left on the metal will severely inhibit the penetration you need in this kind of high-stress application.

Then you will need to weld the spider gears up so they can't rotate. iirc, they can also be welded to the carrier to add some more strength to the frozen assembly.

 

Hope this helps :)

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Remove the differential unit from the housing and unbolt the ring gear. Clean everything up really good with brake/carb cleaner and some shop towels. Once it's clean enough to eat off of you weld the spider gears together. There's four contact points on each side. Make sure that the welds have proper penetration and youl have a bullet proof diff. When everything cools it's a good idea to clean up the slag or flux if your using mig or arc.

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