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Damn I think I really broke something now...

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Re: Damn I think I really broke something now...
« Reply #15 on: March 10, 2012, 07:46:12 AM »
Did this repair to mine more than a year ago, but did not use zip ties.

I Gently pushed the actuator over with a couple screw drivers to engage the axle lock, then ran a bead of weld in the 4 recessed parts of the gear.  The axle lock has alot of material to weld to so you can get good heat penetration.
I have pounded the crap out of mine in mud and snow and has performed flawless.
Don't know why one would use zipties, other than the fact that welding it is a permanent fix, but that's a good thing to me.
A good weld is not gonna break like a ziptie ;)

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Re: Damn I think I really broke something now...
« Reply #16 on: March 10, 2012, 08:58:40 AM »
Some of us don't have the facilities to weld, and zipties are quick & easy - if/when mine fails - depending on where I am when it fails, I know I will have zip-ties handy - a welder - well if it's close to home I might be able to find a friend who can assist.
'98 SQ420 Grand Vitara
'05 JB420 Grand Vitara
'16 APK416 Vitara
'21 A6G415 Jimny

Re: Damn I think I really broke something now...
« Reply #17 on: March 11, 2012, 09:28:09 AM »
You definately have a good point above about the zipties being quick and easy.   I don't have a welder.  I took it to a welding shop, told him what I wanted, took him 5 minutes and he charged $10.00.  The way mine is welded it will never come apart, I will break something else in the diff before the welds fail. 
I installed the axle support bushing, new seals and axles. Its been a year now and I offroad alot with not one problem.
I go hunting and fishing on my own and the fact the ziptie could break would always be on my mind.
For me the extra day the diff was out of the truck is worth not being stranded in the woods because a ziptie broke, but the ziptie thing is an excellent idea for a quick fix.

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Offline nprecon

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Re: Damn I think I really broke something now...
« Reply #18 on: March 12, 2012, 07:32:58 AM »
I don't have decent welding skills (yet) so I took my diff over to a friend who can "weld bubblegum" if you need him to, as Norm always says.  He TIG'd the four spot welds.  It doesn't require much metal penetration and therefore doesn't hurt the heat treatment on the ring gear teeth.  The actuator compressor pushed the ring over with just 6-8 pounds of air pressure, so light tac welds hold just fine.  A good investment for the pocket change it cost and the peace of mind knowing that when you shift into 4WD it's there.  Conversely, IF I ever needed or wanted to do something different in the front end... I'd just buy another used gear cluster for the front.  Short of the front gears or bearings failing.... the only other change I imagine I would opt to go for in the future would be stepping up the gears to 5.12s.
'02 Chezuki Tracker with a 2 Liter and 5spd.  It works for me!!!