Ultimate Guide of Welding Your Differential

Most vehicles have a wide gap, which ensures that the outside tire spins quicker than the primary tire, allowing for the most perfect and practical turning.

Whenever it comes to sliding or wheel spin, the differential should stay locked for robust control, yet as you might expect, welding a piece of metal into the diff is the easiest option to do it. Because the outer wheel must cover a bigger radius with such a welded differential, this should act differently than every automobile on the highway.

And you'll likely encounter hopping, leaping, and possibly even skidding when handling strict circumstances. Here we’ll show you how to weld a diff in steps.

How to Weld a Diff: Step By Step Guide

Step 1:

First of all purchase a welder. You might well have figured, but if you're doing it yourself, the very first step is to buy or rent a welder!

Step 2:

Remove your car's differential. Additionally, as a precaution, you may buy an extra differential to weld. Type of vehicle, these can be purchased for a low price, and spares are always important to have.

Although this step appears straightforward, replacing the differential can be the most difficult aspect of the overall process if you have a rusty back end!

Step 3:

Disconnect the differential plate and pour off the oil. Whenever you separate the differential housing, ensure you have a proper receptacle for the oil so you can drain it out right away.

Some people prefer to use the differential's 'window' instead of dismantling the case, but we will advise removing it to ensure a thorough assessment of the condition.

When you've removed as much fuel as possible, clean the differential as best you can do with non-chlorinated brake cleaners or a comparable product; do not use chlorinated brake cleaner because it can emit harmful fumes when welded.

Step 4:

It's time to weld now that you're satisfied you've drained the oil and cleaned the diff as thoroughly as possible.

Step 5:

Set the welder at maximum throttle, with the optimal speed a little lower than high, and make sure the gear blades are fully heated. After that, weld your differentials together. After you've finished welding, clean up the area to make sure there's no dirt inside, and you're done.

What Happens if You Weld Your Differential?

It's a done thing after you've welded your diff, and if you later regret your decision, your best bet would be to exchange or change it. These gears are enabling your back wheels to revolve at various rates at the moment, so welding them together will harden them, causing your back wheels to spin at the same pace.

Can You Weld Differential Gears?

Yes, you can weld your differential gears. If you drive on the street after welding differentials, your gears, axles, tires, and the rest of your powertrain are safe. At this point, double-check that you've put enough weld into your differential to assure it won't move again, and your task is over.

Can You Weld a Truck Differential?

Absolutely, it can be done as we did with our vehicle’s differentials if you can follow the steps we described above. However, seek to maintain welding equally. It's not a good idea to have doubled quite so much metal solely on a single half of the differential.

Do You Have to Remove Diff to Weld It?

Whenever you'll be welding the differential, it's a smart decision to remove it from the chassis. Only be prepared to adjust your offset and gear teeth pattern. It's a wise idea to mask off areas from shrapnel, such as the rings and bevel gears if you keep the sling in the chassis during welding.

Final Note

This is how to weld your differentials. A welded diff may appear too many to be unsafe and a total waste of effort. It is, however, the greatest alternative if you have an inexpensive rear-wheel-drive automobile that you would like to drift.

Last Updated on 2 years by Richard Boyer

  • June 8, 2022
Richard Boyer

Richard Boyer has been a professional welder for over 27 years of his life, and now he is a trainer and blogger providing critical information to anyone interested in welding. He is helping out both hobbyists, novice and professional welders to learn newer and better techniques. Read more about me

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