Defender Front Axle Case Repair

[Shearpin]

I have a front axle case that has 90 weight seeping through - been bumped a bit and endured decades of winters with a clamp on diff guard. I have stemmed the flow in the past with liquid metal repairs. I don’t think that will be possible again.

Just weighing my repair options for down time and dollars. I have purchased Gywn Lewis products in the past and like the look of their weld on diff cover. Would this option require a complete axle strip down, or could it be welded on with the diff in place by a competent welder?

Any other suggested options? I have the skinny arms - so I assume finding a replacement tube/case to swap would be difficult.

Thanks again,
Henry

 

[Napalm00]

To make it easy on yourself you could just buy a discovery one front axle with the arms. Every other part of the axel will swap over directly.

You could definitely weld a new cap in place with the axle on the truck still, but it's just a pain in the ass

 

[Jbullis]

I put a Gywn Lewis cap on. I took the axle off, then had it welded.

 

[Robert]

I pipe capped one when it got a hole in it and welded it on the truck. Not a great idea. Its near impossible to get it clean enough.

 

[Shearpin]

Thanks for the replies...

I did find a YouTube video of the Gwyn Lewis welding process, and it looks like I need to strip it down to the tube or find a replacement.

Bugger.

 

[Z.G]

I did the sewer cap(did the cutting and the buying, the welding is above my capabilities). Im happy with it, but if I did it again, I'd do the GW weld on heavy duty one, that's a nice setup

 

[FLY CUBS]

PM Sent. I'm about to have an extra front axle available- coming off my 1989 90.