welding rear end

Jeepster05

New member
O2 Sensor

anyone have their rear spider gear welded. my friend has a bonco 2 with welded gears and it seems like a cheap alternative to a locker. what are the pros and cons or doin this?
 

I have herd it is not very strong. If you want it locked all the time spooles are really cheep but either way I would not recomend either for a daily driver. I would go with an auto locker.
 
I´ve got the rear spider welded on my fun truck, trailered to the play ground and back. Wouldn´t even think, of driving it on the street. Driving it around, most any corner or curve, on the asphalt (especially wet), and gassing it, will turn you right around, in a circle (hard on parked cars and other autos). You spend a lot of time, dragging one rear tire or the other along, depending on the road surface and curves. Works just fine, in a straight line, on an even road surface. Works somewhat in loose dirt or mud (easier to drag the off tire)but does effect steering. Could be benefitial in the rocks or timber crawling.
My fun truck has a D 60, which has spider gears, as big as some cars ring gear. Quick spool, is probably a better alternative, if you want to see what it´s like. But like small welded spider gears, I´ve seen a whole lot of failed quick spools.
Deffinetly not recommended for street use.
 

Thanks, S. I've got the diffs welded in the stock D30 and D35 in my '95 YJ and I love it. Great alternative for the best traction, especially since no spools or mini-spools are made for these axles. Search this forum and you'll find some good threads, try searching 'welded diff' or 'lincoln locker'.

I've seen many auto lockers snap the axle shafts on the same trails I wheel on, and I loan them my spare shafts. Luckily (knocking on wood) I've yet to break a shaft. I think the auto lockers are more prone to break shafts.

It's very livable on the street, but you have to have a way to disconnect one or both front axle shafts to run on the street. I have a manual vacuum disconnect.
 
I thought about doing this after my friends who had trail rigs told me that it was just fine. A little more research and some advice from daily drivers, and I was led to not do it. Great if ur going in a straight line, but horrible turning corners, especially in the wet, and it just seems to me like something could be really messed up if some welded material decided to let loose in ur carrier....
 
Depends on who welds it, they must be competent. Done properly it will be the strongest type diff available.

It's really well mannered on the street, you'd be surprised. I was. It wants to track straight, so straight line driving is even more effortless. You don't notice anything in sweeping turns. Tight turns will squeel the inside tire on dry pavement, harder compound tires will chirp the loudest. My BFG MT's chirp a lot louder than my Swampers.

Drives fine on wet pavement, just don't accelerate hard if you have any power (which my 2.5L doesn't). You don't accelerate hard in the snow either, but sane driving is fine and safe. You have to run the front unlocked in the snow, or you can't turn. Need a manual disconnect for this.

This thing climbs like a mountain goat, for me the offroad improvement was well worth the small quircks on the road, and the strange look from bystanders when turning. It may not be worth it for everybody.

I've heard a lot of bad stories about auto lockers in the rear causing sudden lane changes when locking and unlocking, none of that with a Lincoln Locker. Very predictable.

I'd put spools in if they offered them, but they don't, so these are homemade spools of sorts. When I install waggy D44's front and rear, you can bet they'll both be spooled. Mini-spools are less than $75 and replace the spider gears.
 

Well, I know your a pretty competent guy from reading your posts, so I think I will give it a shot. I had just heard they make driving a %$#%^ , but I want off road improvement. So I am willing to sacrifice a little. Any special instructions if I want to have it done?
 
remember bounty, and anyone else who points people to the "search"... every post prior to the forum change is now gone... so many of the topics we've all covered will not come up in a search
 

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Just be sure the spider gears are welded to each other, not to the differential carrier. This will allow the spiders to be removed in one piece after removing the cross pin.

You will still be able to regear using the same carrier and welded spider gears, given the stock carrier is the correct size for the new gear ratio.

I first had mine arc welded and it didn't last, the welds cracked and allowed a little play between the two axle shafts. I was still locked and no damage done. I had another friend MIG weld the spiders, preheating them and the carrier with acetylene, and it has held rock solid, with abuse.

Remember, my YJ is fairly light with a softop and the 2.5L, you may experience different results with a 4.0L and/or a hardtop. Heavier more powerful jeeps are harder on every axle component. I can not stress enough how important it is that the welds are done correctly by a competent welder.
IMG_0819JPG-3.jpg
 
I sprayed my spider gears, with a window pump sprayer, filled with water, constantly, while welding with a MAG, to prevent, softening of the metal (annealing)(welds just fine wet, just use one step higher heat). If the gears soften, it´s right at edge of the weld, which isn´t a bad thing (might bend before it breaks). I used a high carbon gas, which hardened things back up at the weld bead, itself.
I welded mine with an eye, to possibly removing the spiders some day.
I´ve got a like 3500 lb. truck with 300 odd horses. A locked rear end, might be more forgiving, on something lighter and fewer horses.
But personnaly, I wouldn´t do it, to often after a rain (when it hasn´t rained for awhile) the street sweats oil, or somebody spills some diesel or you hit an unexspected icy patch. Fairly sharp left and right curve on a foggy morning. Sooner or later it´s gonna bite you in the butt.
Finding a way to keep the heat down and not soften the gears to much was a tip from a tech. rep. at Diamond gear. He advised agianst welding spiders, said it weakened the gears.
My truck has a tendancy to push, with the rear locked, even with the open front diff, you turn the wheel and it goes straight, for a bit, before it starts turning, on dry pavement, gets worse when things are loose. It increased my turning radius noticeably. I ran at the same track for years, after locking the rear, I had to start turning earlier, to make the same old corners. Takes some getting used to, doesn´t handle the way you expect. While your dragging a tire around a corner, downforce traction is reduced. Something I´d want to practice with, and not go out and drive, in the same old way, I´ve always driven. I´d be real careful on high speed curves or rapid direction changes.
 
Yeah, I may just put in an ezlocker or truetrac, cant beat something with a warranty. I just thought welding would work on the d35 since i am gonna junk it soon. but i live where it rains alot (oregon) so maybe i will just go detroit. which is better, truetrac or ez? I am runnin 31s, soon to step it up to 33s, and I would venture into the rocks much more if i had capable traction.
 

Welded rears work, no questions. They will wear your tires out faster because the inside tire doesn't coast in the turns like a locker (locker doesn't coast either if you are on the gas). With that comes the tire squeal that the cops love so much. Mine tries to push straight off road when on muddy trails. A locker will proably act the same. I have a Detroit Gearless in the front. It is a full on locker (drop in style) but never makes any noise. It performs flawlessly in the woods. They are priced the same as most other drop-ins. The only thing is that you have to use a traction additive fluid every time you change the gear oil. The locker comes with the first bottle and the replacements are $6. It has clutches like a limited slip but they are steel and it works like a locker.
 
I live in the same type of country as Oregon, spend most of my time, on the street or dirt roading, fields and woods. Personally, I prefer a limited slip, it unloads the bias, left and right, more gradually and doesn´t make the old rear end, jump around so much. Pot holes, are rarley the same in both ruts, and the object is to keep forward momentum. Havn´t tried the soft locker. Do some crawling over stumps and fallen timber, I usually manage.
I bought a Detroit locker (knockoff) for my YJ, ratchet type limited slip. Always has had a mind of it´s own, as to when it wants to unlock. Prefer the clutch type, I have now in my XJ, and in my work truck, for daily driving, rain, mud and snow. Or the best 4 out of 5, don´t do much serious climbing.
 
the choice is really tough to make... you can go the easy cheap way... or you can go with a warranty and go expensive... each has the obvious advantages... and each has payoffs... but... regardless of either... the advantages are great
 
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