Going to be doing the 5.12 swap this weekend so I was wondering if it was possible to weld the rear third without disassembling the thing?  I can't set ring and pinion and don't have the cash for anything but welding right now.

Short answer:  NO.


Long answer:  If you match-mark the sidegears as you disassemble it, you CAN weld it and not have to go through extensive setup.  You don't have to mess with the pinion to do this so you don't have to install a new crush sleeve and worry about that part of setting backlash.  This is based on watching and documenting a field-welding of a Samurai differential which is, except for the physical size, identical to the Trackick rear (I have one laying in my garage  ).   

I think it was Quadawg who has a great write up on how to do this. It does require disassembly but he shows you how to put it back together without having to reset everything. Next time I take out my diff I plan on doing it. I think i saved it but it's at work.
Jim

Ended up just slapping the third in.  Karl214 and I got it done after a full day of BSing, fighting rust and crust, and generally trying to fit large hands in spaces that tiny hands would have been better.

It's sitting on stands in the garage right now so the RTV can dry.  Tomorrow all I should have to do is fill the rear diff, bolt up the driveshaft, put the tires on, and then go see how much faster I can conquer some of the local 55mph hills.

Thanks Karl!

What ratio are you switching from?

4.30's