Welding axle tubes

[OU812]

I would like to weld my axle tubes to my diff housing on my ford 8.8 axle. Can this be done with the axle installed on the truck? Anyone done this before?

[kcruisin]

I don't see why not. Make short strokes and alternate sides to keep the heat down.

[dirtman13]

I did mine while they were installed. I agree with kcruisin. Keep the heat down.

[OU812]

Awesome. This is why I like this forum. Within twelve hours of my post I got my answer. Thank you for your help guys.

[pdw]

I would like to weld my axle tubes to my diff housing on my ford 8.8 axle. Can this be done with the axle installed on the truck? Anyone done this before?

*Disclaimer* I am an amateur welder.

From what I have read, welding the tubes to the diff housing can be a bit more complicated than one would think.
1) heating the cast iron diff. with a torch
2) heating the axle tubes to roughly the same temp
3) slow welding - alternating sides
4) cranking up the amp's on your welder in order to get "good heat penetration"

All of that would require that you completely disassemble your axle in order to avoid cooking bearings and things.

Is there anybody that can verify that this process is indeed correct?

[NAILER341]

i welded mine while it was on the jeep. no problem for 4~ years or so

[pdw]

i welded mine while it was on the jeep. no problem for 4~ years or so

Of course! I knew that Nailer would eventually chime in!

So, is the whole routine of pre-heating the pumpkin and tubes unnecessary? I'd like to weld a pair of tabs to the pumpkin for locating my hydraulic assist.

[NAILER341]

clean it up real nice... if you have a mapp gas torch, it wouldnt hurt to heat it a bit to burn off the oils on i. then burn it in there with your mig. it will do fine.

[pdw]

clean it up real nice... if you have a mapp gas torch, it wouldnt hurt to heat it a bit to burn off the oils on i. then burn it in there with your mig. it will do fine.

Nailer,
Let me ask you a relatively obvious question, but I want to be sure....

If I want to weld a pair of tabs to the pumpkin, other than emptying the oil in the differential, do I need to worry about the bearings?

Or are you saying, that because I am only welding two tabs onto the differential it shouldn't be a problem?