welding axle tubes and torque boxes

Mustangog2003

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Nov 18, 2006

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Alabaster,Alabama

Dec 9, 2006

#1

• Dec 9, 2006

• #1

Do u have to remove the whole rearend to get the axle tubes and torque boxes welded up?

 

sgarlic

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Apr 21, 2001

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Dec 9, 2006

#2

• Dec 9, 2006

• #2

no

 

tomustang

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Jun 8, 2000

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McLean Hospital

Dec 9, 2006

#3

• Dec 9, 2006

• #3

but you should, in order to make a consistant 'good' bead you'll have to have each end to were you can reach them without anything in the way

 

Rickey_Bobby

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Nov 8, 2006

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Sarasota, FL

Dec 9, 2006

#4

• Dec 9, 2006

• #4

is there a write up anywhere for this procedure?

 

DTMach1

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Jun 14, 2004

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Virginia Beach, VA

Dec 9, 2006

#5

• Dec 9, 2006

• #5

it's easiest to remove the whole rear-end for the job...gives you a lot more room.

Also, if you have a back seat in, you'll need to remove it along with some of that sound deadning material.

I had 5 or 6 wet towels that I layed across the inside of the car.

You should be able to remove the rear in about an hour.

 

tomustang

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McLean Hospital

Dec 9, 2006

#6

• Dec 9, 2006

• #6

Rickey_Bobby said:

is there a write up anywhere for this procedure?

Click to expand...

Chilton/Haynes is a good start

 

Gearbanger 101

Straight Outta Locash

20+ Year Stangneter

Aug 10, 2002

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Ontario, Canada

Dec 9, 2006

#7

• Dec 9, 2006

• #7

Didn't either MM&FF or 5.0 Mustang give a detailed article on it in last months issue?

 

Rickey_Bobby

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Nov 8, 2006

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Sarasota, FL

Dec 9, 2006

#8

• Dec 9, 2006

• #8

Hmm... The "custom modification" section must have fallen out of my haynes manual.

...I'll have to check out those mags tho. If not, I guess a case of beer and the welder will net some sort of result.

 

DTMach1

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Jun 14, 2004

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Virginia Beach, VA

Dec 9, 2006

#9

• Dec 9, 2006

• #9

just remember if you're using a MIG you'll need to adjust the voltage for the different thickness metals...at some points its pretty thin.

 

BlueRuckus

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Jun 30, 2005

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Miami, FL

Dec 9, 2006

#10

• Dec 9, 2006

• #10

Check it.

http://www.************.com/?show=articlesdet&aid=14

MM&FF also recommended taking it down to do it.

 

BlueRuckus

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Jun 30, 2005

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Miami, FL

Dec 9, 2006

#11

• Dec 9, 2006

• #11

Hey what's up with the link I put?!

 

BlueRuckus

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Jun 30, 2005

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Miami, FL

Dec 9, 2006

#12

• Dec 9, 2006

• #12

Anyway. Go to the Modular Depot website and go to the articles section and look up the one called:

Welding Your Axle Tubes and Torque Boxes

 

S

Smokeurhonda

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May 1, 2003

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Maryland

Dec 10, 2006

#13

• Dec 10, 2006

• #13

Thanks for the link!

 

BennyBlown2v

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Dec 9, 2004

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Carmel, INdiana

Dec 10, 2006

#14

• Dec 10, 2006

• #14

I did it with the rear end out. Wasn't hard. For some of the larger gap welds in the torque boxes start by making large clean tacs, then welding from tac to tac slowly. This will also reduce heat stress, and the likely hood that your carpet will light on fire lol

 

the98stang

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Aug 12, 2005

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Clovis, CA

Dec 10, 2006

#15

• Dec 10, 2006

• #15

I heard that the axle tubes couldn't be welded unless the differential was heated a certain way because the metal material is very hard to weld

 

BennyBlown2v

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Carmel, INdiana

Dec 10, 2006

#16

• Dec 10, 2006

• #16

the98stang said:

I heard that the axle tubes couldn't be welded unless the differential was heated a certain way because the metal material is very hard to weld

Click to expand...

The problem is that with MIG you have to crank the voltage up alot to penetrate the diff housing, but when you do that you risk burning straight through the axle tubes. Using a small MAAP gas torch, or even a propane torch if thats all you have, to pre-heat the axle housing might help a bit. Big thing is go really, really slow. If I was do to it again I would have done the axles with a stick welder because it lays down such a wider bead, and penetration is pretty much uniform with a decent pool - either that or learn to TIG

 

R

rpburnette

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May 22, 2003

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Tampa, FL

Dec 11, 2006

#17

• Dec 11, 2006

• #17

I thought the housing was cast, if that is the case, than you will need to heat the housing. Cast metals are hard to weld correctly. Sure, you can lay a weld down, but if you improperly weld cast metal, than it could cause damage. The idea is to evenly heat the cast metal before you weld.

If the housing is not cast than just disregard the statement above.

Now I have a question. If you weld your axle tubes to the housing, would the heat of the weld hurt anything inside the housing such as grease or bearings?