Procedure:

1. Remove the Wheel ends and Drive head from Housing.

1. Clean the Housing inside and outside 3” away from the area to be welded by removing the dust / Oil / Paint.

1.  Remove the Cover weld from the cracked area of Housing

• Apply an anti- spatter compound on the housing area around the weld that will be cut. If you do not have an anti –spatter compound, cover the axle housing with a nonflammable cloth.

• Attach the ground cable as near as possible to the cracked weld area and only to components welded on the axle, such as a housing spring pad. Do not attach the ground cable at a suspension spring, U-bolt or at a point that places a wheel bearing between the ground connection and the weld area.

• Gouge approximately four grooves into the housing–to-cover weld crack area the full length of the crack plus an additional one inch (25.4mm) past each end or side of the crack.

• After gouging is completed, remove any thick amounts of weld material that remain on the housing and cover with rough grinding.

               CAUTION

Replace the housing if you find cracks in the housing material or cover material. Do not repair weld cracks in the housing material or cover material. Damage to components can result.

• If the crack in the weld extends by more than 1/3 of the circumference of the cover, 20 inches (508mm): The housing must be replaced.

WELDING

a)     Outside of the cover to the housing

              Position the housing for a flat weld by tilting it 45 degrees forward.

 b)     Inside of the cover to the housing

Position the housing for a flat weld by rotating it 180 degrees from the operating position it would be in under the vehicle. The oil drain hole will be at the top position and the center line of the housing must be vertical.

1. Use suitable weld wire electrodes when you weld. Suitable weld wire electrodes include either BS EN 499-E42 2B32 H5 or BS EN 440-G422MGSi (American welding society equivalents E7018 and ER7063, respectively).

1. Lay a full fillet in a single pass, if possible, to the end where the damaged weld was removed plus one-inch (25.4mm) past the end (into the old weld)

1. When multiple passes are required to obtain the correct single-flare bevel weld size, remove all slag and flux from the last weld before applying the next weld.

1. Clean and inspect the final weld.

1. Install the drive head, Wheel ends on Axle Housing and fill axle with the specified type and amount of lubricant. Refer to vehicle manufacturer’s instructions.