stress crack in front diff housing

[downforce137]

this developed over the weekend at silver lake sand dunes. must have been dripping on the highway drive home in 2WD of course..

i know a few have had this issue over the years, and im also out of the powertrain warranty, not that id really expect it to be covered.. so weighing options..

1. new axle housing is around $400+seals, shim kit and crush washer, reuse all bearings, R&R this diff, and swap internals into a new housing

2. used ebay housing, haven't really looked but assume a raptor diff is $500-$1000

3. try having the crack welded by some pros at repairing damaged motorcycle engine cases.

4. ? any other ideas?

seems like it needs some more support in the form of gussets or some kind of wrap around brace to support the middle area of the entire housing

 

[GCATX]

I would have it welded.

 

[fordfreek]

How far out of powertrain warranty are you? Might be worth a call to customer care to see if they can help you out. Might be the cheapest and easiest route. Ford should eat something like that.

 

[downforce137]

How far out of powertrain warranty are you? Might be worth a call to customer care to see if they can help you out. Might be the cheapest and easiest route. Ford should eat something like that.

5 years in service date at the end of this month and 65k miles

 

[JohnyPython]

I second welding. Unless you can find a used one.

 

[Sig Fanboy]

Dang, that doesn’t look to Baja capable. I’ve got a guy who works for me that could probably weld that. It’ll take some prep. Maybe it was just a bad casting that finally cracked. Guess you could try some JB Weld to start, that stuff is pretty good.

 

[fordfreek]

5 years in service date at the end of this month and 65k miles

I'd definitely call Ford. I think they would help you out. Unless you're heavily nodded or you don't trust your dealer.
Otherwise, I'd probably replace the housing myself .

 

[wazatataza]

I think you should find a local friendly dealer... if it exists...

or as others have said. weld it!

 

[downforce137]

I think you should find a local friendly dealer... if it exists...

or as others have said. weld it!

Don't have one around here.. they see an intercooler and shock reservoirs and don't want to do anything, i don't really expect them to be any help..

 

[rschap1]

How crazy did you get at the dunes???