G16A Rear Diff CRACKED

[smallblock450sl]

Sorry to say those gears are bad. Also, the "idler" gear on the outer case will need replacing.

[allergic2sailboats]

Thanks for the replies, the guy might be welding up the case tomorrow, I will show pics of that after its finished. As for the gears, I am on the look out for some gears.. I am going to look in to saving whatever I can save. I all ready have too much money into this, so I either am at the point where I throw the bank at it.. or try to pinch and save on the rest and hope that the old parts I cheaped out on don't destroy my new parts I spent top dollar on. I know a guy that works magic with metal... I will see what he can do... will post pics of whatever course of action I decide..

As for the idler gear, that was the one I didn't show pics of.... it's probably my best one... the pinion gear is another story,,,

[allergic2sailboats]

Hello everyone, it's been a while. Back with an update.....

Got the transasxle welded up. So for the gears, I did not replace them. I filed them down. Any spot that was mushroomed in a little bit I hit it with a file and a grinding stone. When I put everything back in the axle everything seemed to line up just fine. Assembly was pretty straight forward. I found some pictures that someone took of their input shaft install, that helped out alot. Also I used the parts manual so I remembered where the washers or any other part went. I messed up and did not take a whole lot of pictures. I wish I did... so I got everything together 3 days ago and yesterday I took it around 15 miles or so, and no issues. Well my drive clutch plate was coming loose but I didn't even mess with that during all of that... So the axle has 80-90w in it now and it holds it!!!.. NO MORE GREASE and no more HOLE.... WOOOHOOOO.

I was very surprised that the gears were not noisy at all. everything sounded the way it should. I don't see why those gears won't last for years to come. Just change my oil every year and should be good to go.

[allergic2sailboats]

Also I did the Bluing thing that Robert was talking about. That helped alot. I used bluing to help me when I was filing as well. I did not file any of the top part or face of the spline, just the mushroomed out parts. And I filed everything until the gears that needed to mesh together lined up perfectly.. then I installed. The re-assembly took me only a few hours... The filing of the gears with a stone took me 4 days, a few hours a day. It was very time consuming. However, I ended up doing alot of the filing while i was watching tv or just relaxing.

[smallblock450sl]

Good for you I would suggest getting rid of that dreaded "White" spring.

[robertakamagoo]

I'm glad it worked for you.

[allergic2sailboats]

the white spring came with the plowman cart torque kit... is that the bad spring to have? It was alot thicker and heavy than the black one that came out....

[Shepard]

Excellent save and a great weld job. What type of drain plug does it have? If it's magnetic all well and good ------ if not You might consider putting a big flat magnet on the tin cover to filter out any metal flake in the oil as the parts wear in.

[allergic2sailboats]

Had some setbacks so never put a plug in it. I gave him the case without the main drive gear, so when he welded it back together the gear did not fit back in it, not a big deal it just took longer than expected.

I plan on driving it around pretty good the next few days then draining and refilling soon. I am surprised that it isn't leaking, I bet it will leak eventually but so far so good. I was going to replace the axle seals, the cart place sent me the wrong ones so I used the old ones that were leaking previously, so far they are not leaking but eventually I am sure they will. The magnet would be a good idea. I am sure there is going to be some metal crap in there. I am hoping this is a permanent fix and not just a band aid. Only time will tell....

Even though I went cheap, it still wasn't a cheap fix... due to the fact the input shaft was 300 bucks. A used rear end was 600-700 maybe I should have went that route, but I would not have learned all this stuff about the rear end, and swapping rear ends is just plain.... BORING... plus I only paid 600 for the cart so paying 600 for a rear end seemed ridiculous...


I really think i could have gotten rid of the the governor stuff on the input shaft and cleaned up input shaft and that may have worked. But being how important the shaft is.. i decided to go new.