Porous Rear Diff Pan

I've been wondering why my rear diff was slightly leaking despite changing the pinion seal so I had a closer look and found a tiny hole in the diff casing. I got my head welder (mate) to neatly weld a small plate over the hole and after a quick spray with Waxoyl you wouldn't know it was there. So two days later when I'm underneath greasing my props and UJ's I noticed a drip of EP90 coming from under the diff. As I can't see a particular point it's coming from I can only assume it's gone porous ... So, my question, I have searched and found that you can seam weld a new pan on there but is there any magic liquid of any description that you can spray on or pour in that is effective at least in the short term? All the cash I've spent on getting it through the MOT means I'm looking for a cheap short term solution. Any ideas anyone? ... oh and don't say chewing gum

There are a number of 2-part epoxies available which have similar properties to the parent metal.

I have used them on bronze, cast iron, stainless and copper ... as I say, there is one for each specific use.

However, you have to be scrupulously clean with not a trace of oil, grease or any other contaminant otherwise they don't work!

Trouble is that at the moment I can't remember who makes them!!

Plastic Padding Chemical Metal Repair Paste

It can be drilled and tapped, if needed, i've used it and it's ace

Cheers guys ... at least I know there's something out there so I'll take a look at the Plastic Padding option.

I have tried this it lasted for around 3 weeks until the oil started coming out of the hole and going between the diff and the padding and created a bubble until it popped and I ended up with oil going everywhere. I am going to have another go at it as I think I didn't clean the area enough before I applied the Plastic Padding. Let you know how it goes.

I had the same on a disco, i used metal putty, i drained the diff and heated the casing up to make sure there was no oil to stop the putty bonding...lasted the time i had the disco

i had the same problem - i removed diff, cleaned inside & out with petrol, tapped the pan in slightly to open up the crack (not too much - there aint much clearance) and then used metal mastic as a "rivet" - it lasted for over a year till i sold the motor.

I ended up getting a new diff pan and seam welding it in place ... all good now

Andy Land said:

I ended up getting a new diff pan and seam welding it in place ... all good now

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would seem i have the same problem as the op, when you got the replacement diff pan and you welded it do you leave the old pan in place? and did you have to take the axle off to do it or can you do it in situ?

cheers

mandy

ps i only had a small leak until it was inspected n now its p ing out

lcbandit said:

would seem i have the same problem as the op, when you got the replacement diff pan and you welded it do you leave the old pan in place? and did you have to take the axle off to do it or can you do it in situ?

cheers

mandy

ps i only had a small leak until it was inspected n now its p ing out

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Cut old one off.
I used chemical metal from halfrauds never leaked after that

craigyb said:

Cut old one off.
I used chemical metal from halfrauds never leaked after that

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easy when you know how lol well volunteered craig

Cut old one off with a grinder carefully and then seam weld all the way round.
Should take about 2-3 hrs

http://www.landyzone.co.uk/lz/members/andy-land-albums-stuff-picture10467t-rear-diff-pan-cut-off.jpg

Here you go ... easy

Bigger images in my photos in the 'Stuff' folder.

ok thanks for that, but I dont posses a grinder n a wouldnt know where to start with welding, id probablly put a hole straight through lol, im lucky that craigyb doesnt live 2 mins away and has offered his help which i have gladly accepted lol gonna temporaryly metal weld it myself til a new pan fitted, i can do that myself did it on a casing on my bike!! clever girl me lol

lcbandit said:

ok thanks for that, but I dont posses a grinder n a wouldnt know where to start with welding, id probablly put a hole straight through lol, im lucky that craigyb doesnt live 2 mins away and has offered his help which i have gladly accepted lol gonna temporaryly metal weld it myself til a new pan fitted, i can do that myself did it on a casing on my bike!! clever girl me lol

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Good stuff ... hope it works for you