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ZUKIWORLD Discussion Forum => Technical Discussion - Performance / Modify => Topic started by: Phase change on November 14, 2017, 04:48:01 PM

Title: Air actuated front diff weld-out completed.
Post by: Phase change on November 14, 2017, 04:48:01 PM

Thought I’d post up a pic of my project today.  I’ve been on a defeating tour around my new Suzuki and the tour came to a climax with this mod.  Okay so after removing diff (kinda hard, not too bad tho) remove third member.  This requires long side axle removed.  This is accomplished with a big ass hammer and careful swings.  Use a piece of tubing or something that will let you bang close into the shaft so you don’t bend the ears on the flange. 
Once out I applied air to the system so I could see what was going on.  I couldn’t hear a leak but i don’t want the chance of a fail on here.  I left the air applied while I tacked the parts together in the 4 locations around the carrier.  You want to do this in fully assembled condition because otherwise you could weld it too far engaged and cause binding on assembly. 
These parts are unknown metal and could be quite brittle so I used a silicon bronze fill wire.  Placed 4 small welds.   Screwdriver is pointing to one of the welds. 

Replace parts, goop the two halves and re install. Don’t forget to put oil back in!

Anyway hope this helps someone as I found little info on it.  The member recon was a great resource and got me going on it.  I’ve heard some folks use a ring and install it in there but as a welder I chose this method as it seemed a lot easier. 

Title: Re: Air actuated front diff weld-out completed.
Post by: 40nTheFloor on December 03, 2017, 03:40:34 PM

Yes, this is an excellent reference for all of us.

Title: Anybody know what this is?
Post by: oddsox25 on December 05, 2017, 12:21:10 AM

Anybody know what this rusty part is called?

cheers

Title: Re: Air actuated front diff weld-out completed.
Post by: fordem on December 05, 2017, 11:00:38 AM

The transmission cross-member from the looks of it.

Welcome aboard, and please be aware, it's considered impolite to post unrelated questions into someone else's thread, better if you start your own.