View Full Version : Rear Diff Cover 1994

07-01-2007, 06:44 PM
Rear Diff is leaking and I noticed a spot of rust on the bottom of the diff cover. Very weak and like a sponge of fluid. I see there is a diff cover RN offers. How hard is it to get the old one off/new one on and any tips doing so? Is this a mig weld job?


07-02-2007, 06:58 AM
That's a common problem on older Discos. It's not a hard job. requires cutting the old one off, grinding it flush and welding the new one on.
Proper (Gas Shielded) MIG is the best way, but you could do it with 3/32" stick and low current also (SMAW). The inside (and outside needs to be thoroughly cleaned, so that you have no porosity in the weld. If you're not using a welder regularly, you may be best served by going to a good welding shop. Have a new gasket with you so they don't have to reuse the old one. Popping the differential out is well withing the capability of a welding shop, but quality welding isn't always gotten from the LR shop, though a good indie may be up to it.