Leaking 9"

[BroncoJimbo]

The oil spot has been getting pretty big and it looks to me like the seam around the outside of the pumpkin is seeping. I don't suppose there is any other way to repair this other than taking it out to be welded? Ignore my useless attempt at using JB Weld.

 

[Yeller]

I’ve welded them full of oil but can be hit or miss (usually at the race track) best results just drain the oil clean very well and weld it up. This is a good time to pitch using lube locker gaskets. Unbolt the 3rd enough to drain the oil, repair, retighten the nuts and refill with oil. I have drilled a 3/16” hole in the bottom to drain, make the repair, weld up the hole and refill. Lots of options, just have to suck it up and do it. FYI, this is fairly common issue.

 

[DirtDonk]

Is that the original rear diff in your rig Jimbo? Is it a standard early housing, or is it the later reinforced housing usually used in the 77 models?
Looks more like the later style, so I was curious. If it is, what month was your bronco built in?

 

[Broncobowsher]

I've welded them full of oil. The first pas is super ugly as it is burning off the oil. But a fat weave over that to grab good metal on each side and bridge the porosity of the first pass. Big fat weld in the end, but not leaking, never took it apart. Ran it hard.

Usually that is the second weld to break and leak. The first is usually the passenger side, front of the housing. The weld on the flare just before the center section. I've seen multiple Bronco's crack that one. The back cover cracked weld always had that flare crack first.

 

[Apogee]

If you do strip it down, I'd recommend hot tanking it and/or hitting it with a torch/rosebud for a while to cook as much oil out of the crack/seam as possible before putting a welder on it, otherwise it'll be more porous than a sea sponge when you're done. Like 'bowsher pointed out, you can cover it with a gorilla weld, but it probably won't be pretty.

 

[BroncoJimbo]

Is that the original rear diff in your rig Jimbo? Is it a standard early housing, or is it the later reinforced housing usually used in the 77 models?
Looks more like the later style, so I was curious. If it is, what month was your bronco built in?

AFAIK it's the original rear. I've owned it since 1990 but who knows what the PO might have done. It was built 3/3/1976.

 

[BroncoJimbo]

Thanks everyone. I think I will end up pulling it since I need to replace leaking axle seals. Again. I may have to replace the axles since I can't seem to keep them from leaking.

 

[DirtDonk]

Are they standard axles with an inner seal? Or are they heavy duty upgrades with the tapered roller bearings?

 

[BroncoJimbo]

Are they standard axles with an inner seal? Or are they heavy duty upgrades with the tapered roller bearings?

Standard, I believe.

 

[bigmuddy]

If you do strip it down, I'd recommend hot tanking it and/or hitting it with a torch/rosebud for a while to cook as much oil out of the crack/seam as possible before putting a welder on it, otherwise it'll be more porous than a sea sponge when you're done. Like 'bowsher pointed out, you can cover it with a gorilla weld, but it probably won't be pretty.

No lying. I tried this years ago including the JB weld, still leaks but I am a mere mortal when it comes to welding.

 

[Broncobowsher]

If you do strip it down, I'd recommend hot tanking it and/or hitting it with a torch/rosebud for a while to cook as much oil out of the crack/seam as possible before putting a welder on it, otherwise it'll be more porous than a sea sponge when you're done. Like 'bowsher pointed out, you can cover it with a gorilla weld, but it probably won't be pretty.

That gorilla weld had a nice stitch pattern to it and looked pretty decent.

 

[Timmy390]

If it were mine.....I would jack it up so the oil is in the opposite tube, wire wheel the heck out of it to get the JBW off. Then propane torch the crack/seam to wick the oil out of the crack. Then degrease it and yes I know the dangers, spray break clean into the cracks. Once dry, I would heat the area again and see if any oil wicks out. If not, weld away.......If worried about fumes from the brake cleaner on the inside, yank the axle and let it air out before heating and welding.

I've see Jeeps with leaky front diffs welded with a stick welder with no prep. Ugly.....but didn't leak

Tim

 

[BroncoJimbo]

No lying. I tried this years ago including the JB weld, still leaks but I am a mere mortal when it comes to welding.

Yeah, I'm a hack welder but a decent grinder.