Mark151151
Active Member
Well after my rear diff decided to fall apart and destroy the diff casing I decided to build a new slightly heavier duty casing, I know there are various company's who produce HD diff pans off the shelf but there's something satisfying about making your own parts and saving some money while you go.
Here's what I started off with: basically the circlips which hold the centre diff pin in fail causing the pin to fall out and punch a hole in the diff pan, this can be seen at the bottom of the tear! In the picture below, Then I kept driving and the gears which fell out tearing the pan wide open.
So here's what i started with today:
Start by flushing out the gas bottle so you know there's no chance of an explosion when you start cutting.
Next cut off the old diff pan and buff away the welds and any remainjng material on the axle and use it as a rough guide for a diameter to cut the bottom of the gas cylinder.
Now you will need to decide how far out you need the base of the gas cylinder to sit from the axle. Iv worked mine out to be 55mm so I masked off a 55m band around the gas bottle and cut right round the bottle
Now use a small ratchet or similar to reduce the size of the ring until its the right diameter to suit your new pan, then mark and cut off the excess and weld it so you have a large hoop.
Both these parts can now be fully welded to the axle
Next you need to cut out and weld in the fill/level plug
And the jobs done, just need to give the axle a really good clean out and paint and fit all your parts.
We also had the circlips removed and the diff pin welded up in the new diff so there's no chance if it failing for the same reason again. Will add the picture when I find it.
Hope this can help some people.
Cheers mark
Here's what I started off with: basically the circlips which hold the centre diff pin in fail causing the pin to fall out and punch a hole in the diff pan, this can be seen at the bottom of the tear! In the picture below, Then I kept driving and the gears which fell out tearing the pan wide open.
So here's what i started with today:
Start by flushing out the gas bottle so you know there's no chance of an explosion when you start cutting.
Next cut off the old diff pan and buff away the welds and any remainjng material on the axle and use it as a rough guide for a diameter to cut the bottom of the gas cylinder.
Now you will need to decide how far out you need the base of the gas cylinder to sit from the axle. Iv worked mine out to be 55mm so I masked off a 55m band around the gas bottle and cut right round the bottle
Now use a small ratchet or similar to reduce the size of the ring until its the right diameter to suit your new pan, then mark and cut off the excess and weld it so you have a large hoop.
Both these parts can now be fully welded to the axle
Next you need to cut out and weld in the fill/level plug
And the jobs done, just need to give the axle a really good clean out and paint and fit all your parts.
We also had the circlips removed and the diff pin welded up in the new diff so there's no chance if it failing for the same reason again. Will add the picture when I find it.
Hope this can help some people.
Cheers mark
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