Hole in rear Diff.

[dale7637]

Hey guys, i have a 2005 f-350 Drw that is down right now. The truck took a rock in the front of the diff casing and there is a hole about the size of a golfball in the case. Is this something that can be welded? Or will Axle housing need to be replaced? Thank you very much in advance. Also, does anyone know where i can track down a service manual to rebuild this diff? Thank you.
Dale.

 

[RoyBoy]

I would think someone that knows what they are doing could weld it, depending on where the hole is. If you had a good picture of the damage it might be helpful.

 

[Tail_Gunner]

I say replace it.

1. If you're going to weld it, you're gonna want to remove it first. Otherwise welding by-product may enter differential.
2. If you have a hole, you're gonna want to remove it to inspect for foreign matter from the damaging impact that may have entered the differential.
3. If you had an impact hard enough to punch a hole in the cover, you must consider the possibility of damage to the gear set and/or differential unit.

In any case, take it off. If you do that, might as well save the trouble of a crappy looking "patch job", and just put a new one on. Might even be able to put a HD armored cover built for the abuse of off-roading.

 

[DaveBen]

X 2 on the replace it. Too many factors in just welding it up.

Dave

 

[RoyBoy]

I think you guys missed the fact that he put a hole in his housing, not the cover...unless I understood wrong. We're talking serious dollars here. (don't ask how I know )
I still want to see the damage picture

 

[Tail_Gunner]

I think you guys missed the fact that he put a hole in his housing, not the cover...unless I understood wrong. We're talking serious dollars here. (don't ask how I know )
I still want to see the damage picture

Now that I re-read the O.P., it could be taken either way.

Even if you look at it from the other perspective, FWIW, I've heard welding cast iron isn't something for beginers, not like welding steel. If it is a hole in the front of the rear diff, I'd be shopping for a used rear end.

Clarification required.

 

[Bad Night]

Yea , I say replace it too . Taking a hit that hard the pumpkin could be out of shape which would change all of the tolerences and cause bearing and possibly gearset problems .

 

[JLDickmon]

not to mention that to weld cast iron, you need to heat it with a rosebud untill the whole casting is cherry red..
the pack it in firebrick for a slow cooldown.. not anything you can do in an afternoon..
so I think a new case is in order..
be easier..

 

[dale7637]

I have an update.. The hole is in the housing itself, not the cover. I was just unloaing it off of my lowboy and she locked up tight. Tore the cover off in the shop and this thing is cabbaged. There is going to be no saving it. A chunck of the housing got picked up in the gear set and made a mess. For some reason i cannot load pics, so i will try again in a bit. Thanks for the help guys.

 

[dale7637]

Pictures are here.