Outer Limits 4x4 Board

Just under the 80 series today changing the oil when i noticed the RHS front diff mount had broken off compleatly.

Must of been a while ago as there is a little rust on the broken welds, being a lifted suspention you get used to not having a solid suspention so i never realy noticed any difference in the ride.

So my question is what to do about it ?
Is it as easy as just welding it back on or is there more involved ?

If you look at the first pic at the botton there is a half circle piece of metal missing from factory compared to the LHS one on the last pic, this obviously had to do with the breakage.

** click on the other 3 pics for photo. (for dial up users)


http://img.photobucket.com/albums/v298/Kev80/RHS2.jpg
http://img.photobucket.com/albums/v298/Kev80/RHS3.jpg
http://img.photobucket.com/albums/v298/Kev80/LHS1.jpg

Have seen this a few times, in the photo's it looks damp so a crack may go through allowing diff oil to seep out. if its to be rewelded as it is possible the crack in the housings needs to be repaired first and then the bracket rewelded. Every time i have seen this happen has been on lifted 80's using Urethane caster correction bushes. I beleive they are way to stiff so when articulating the mounting brackets are highly loaded. I have redrilled housing to correct caster that way the original Toyota bushes can be used and never seen them crack mounts when done like this.

Wally.

Yeah it must be a very small hole as i couldn't exactly see where it was coming from.

Might have to look at maybe redrilling the holes in the future.

Since you have seen this before has anyone tried reinforce the brackets some how ?

If the bracket's reinforced where it attaches to the diff housing it only 4mm thick material and causes cracks in the housing. I would suggest repair the bracket and fit the Toyota bushes an it will be fine.

Wally

I was talking to the guy who does all the welding at a engineering shop today and he said he could make all the mounts stronger but to do that i would have to remove the whole diff housing and bring it in. Still deciding if to do this or not.

Last thing i need is for it to fail again half way up the Cape etc so i want it done right.

Looks like i will take your advice and re fit the factory bushes as i saw them today and they do look more flexable.

How do you know where to drill the new holes ?
Do you have any pics of your set up ?

Cheers.

Edit- just looking at it now it looks like it would be very difficult to re drill the bolt holes as the diff center is in the way, not sure how you would do this.

How bad would it be if i fitted factory bushes without redrilling ?