Welded diff with problems..

[LostKen]

I have welded the diff once before Xmas, and it was broken down after 2 days..since then, there is noise from the gearbox and drive shaft. ( should be)

I thought it was the noise from the diff but after I welded it up again last week, it was still here.
Obviously the noise I am referring is not the jumping/tyre voice when turning, it is some sort of gear noise when accelerating and deccelerating in 1,2 and 3rd gear. When I changed to 4th, 5th gear,the noise has reduced or even disappeared.

Is it something about the gear box or the diff?? Is it still safe to go on as I dont want to break anything when I am doing 60 in motorway lol

Any advice??

Cheers

Ken

[sven360]

I have welded the diff once before Xmas, and it was broken down after 2 days..since then, there is noise from the gearbox and drive shaft. ( should be)

I thought it was the noise from the diff but after I welded it up again last week, it was still here.
Obviously the noise I am referring is not the jumping/tyre voice when turning, it is some sort of gear noise when accelerating and deccelerating in 1,2 and 3rd gear. When I changed to 4th, 5th gear,the noise has reduced or even disappeared.



Any advice??

Cheers

Ken

Buy a limmy/

[volvodspec]

separate the diffhousing from the gearbox, take the diff out and check the crown and pignonwheels for damaga/missing teeth.

dit you place the shims of the halfshaftcovers back correctly?

[LostKen]

separate the diffhousing from the gearbox, take the diff out and check the crown and pignonwheels for damaga/missing teeth.

dit you place the shims of the halfshaftcovers back correctly?

Yes I did place the shims of the halfshaftcovers back correctly, but i think the problem should due to the weld broke down on the first time in the diff and damge some of the teeth. I have welded it back properly so i dont think the sitaution will get worse. Just wanna ask if it is safe to drive on with present condition despite the noise( some damge on the teeth)??

Cheers

[Speedy88]

It's safe to an extent but you don't want be stranded if the teeth all sheer off one side

[LostKen]

I have cleaned the diff out the second time, so i think the noise should be just the little damaged diff running (now without those loose bits in there)
BTW, why will the noise dissappear when I change to 4th and 5th gear though? dont understand the theory....
or is it the gear box problem

[volvodspec]

were the sprockets damaged allready?

if you found loose bits of tooth then the diff is pretty much a write-off, especcially if you run a welded diff were the crown and pignon sprockets have even harder load than normal.

if you don't want more teeth to break off the sprockets, use a piece of rounded steel and hammer teeth by teeth in two directions. problem with the loose bits getting inbetween the sprockets is that they can cause direct damage and slight cracks. this way you really leave the good teeth on the sprockets rather than having loose teeth again after a few corners/miles.

noise could probably be gone in 4th/5th because enviroment noise takes over?

if the noise is present on the same speed in 3rd and 4th/5th than the problem is in the gearbox since the diff then still has exactly the same speed.

[LostKen]

were the sprockets damaged allready?

if you found loose bits of tooth then the diff is pretty much a write-off, especcially if you run a welded diff were the crown and pignon sprockets have even harder load than normal.

if you don't want more teeth to break off the sprockets, use a piece of rounded steel and hammer teeth by teeth in two directions. problem with the loose bits getting inbetween the sprockets is that they can cause direct damage and slight cracks. this way you really leave the good teeth on the sprockets rather than having loose teeth again after a few corners/miles.

noise could probably be gone in 4th/5th because enviroment noise takes over?

if the noise is present on the same speed in 3rd and 4th/5th than the problem is in the gearbox since the diff then still has exactly the same speed.

I am not sure about the sprockets if it has already damage or not ( probably it has coz the noise)

But I am quite sure that the noise disappear or decreased dramatically in 4th/5th gear at the same speed, does that mean the problem is on the gear box not the diff??

The noise is there when accelearting and espeically in deccelerating....so im not sure whether it is the gearbox or the diff problem...


If that is the noise from gearbox, is there any danger driving it daily???

Cheers